Strip of collated fasteners and related methods of use

ABSTRACT

An installation tool and related methods are provided. The tool can pull a strip of collated fasteners along a collated fastener path to a guide, where individual fasteners are sequentially separated from the strip and advanced into a workpiece. The tool can include a tension feeder located downstream of the guide. The tension feeder is configured to apply tension to the strip between the guide and a leading end of the strip. The tool can include a driveshaft configured to attach to a conventional drive tool chuck or a drive tool having hexagonal type drive components. The guide can be one piece and replaceable, with a guide body and a guide head. A strip slot can be defined in the same to align a fastener head with a backstop and facilitate entry of a fastener shank in a feed slot. Related methods of use are provided.

BACKGROUND OF THE INVENTION

The present invention relates to fasteners, and more particularly, to atension fed fastener installation tool and a related method of use.

There are a variety of fasteners, such as screws, that are used widelyto fasten objects together or attach one object to the other. Cordlessor electric installation tools are frequently used to drive screws tosave time and increase work efficiency. Many installation tools, such asscrew guns, use collated screws to further increase the work efficiency.In use, most screw guns operate to feed a flexible collated strip ofscrews from the bottom of the tool toward the nose of the tool, wherethe individual screws are separated from the collated plastic strip anddriven into a substrate or object.

Most conventional screw guns include a special pusher feeder. The stripof screws is fed through the gun via the pusher feeder, which engagesnotches in the sides of the collated strip with one or more teeth. Theteeth are advanced by some action of a user, for example, via the userpushing the tool toward the substrate or object, so that the teethengage a few select side notches, and push the collated strip toward thenose of the tool for driving.

While conventional screw guns with this type of pusher feeder work, theysuffer a variety of shortcomings. First, the pusher feeder many timesrequires a complicated mechanism to actuate the teeth with some sort ofmotion imparted on the tool by the user. This mechanism may utilize aseparate drive that rotates a toothed gear to push the strip when theuser initially pushes down on the tool. Second, in some cases, theforward push of the strip toward the nose must be perfectly timed, orthe pusher feeder may create a jam or a misfeed of the strip. In turn,to fix the jam, the user typically disassembles the nose piece, whichcan be time consuming and frustrating. Third, the flexible screw stripscan be difficult to manage, and at times it is difficult to prevent thescrews on the flexible strip from bunching or tangling as the strip ispushed toward the nose piece for a driving sequence.

Accordingly, there remains room for improvement to provide aninstallation tool and related method for fasteners in a collated strip,where the collated strip is fed more efficiently and is less prone tojamming, misfeeds, bunching and/or tangling.

SUMMARY OF THE INVENTION

A fastener installation tool, a strip of collated fasteners and relatedmethods of use are provided. In one embodiment, the installation toolincludes a frame, a guide joined with the frame, and a tension feederconfigured to pull a strip of collated fasteners along a collatedfastener path. The tension feeder is located downstream of the guide andconfigured to apply tension to a portion of the strip between the guideand a leading end of the strip.

In another embodiment, the tool tension feeder includes an elongatemember that coils retractably into a roll. The tension feeder caninclude an attachment element, such as a pin, that is configured toattach to the leading end of the strip to facilitate pulling it throughthe tool, and the guide in particular.

In still another embodiment, the tool can include a guide having a borethrough which fasteners are advanced out the tool. The guide can includea guide wall adjacent the bore and a fastener stop, also referred to asa backstop, adjacent the guide wall. This fastener stop can arrestmovement of a fastener along the collated fastener path so that a tipand/or shaft of the fastener swings into alignment with the bore,optionally when the head collides with the fastener stop.

In even another embodiment, the tool can be outfitted with a guideincluding a head size adjuster element that is configured to engage acorresponding backstop so as to set the guide to accommodate apreselected head size. Optionally, the head size adjuster element isadjustable so that different sized guides for different sized fasteners(for example, different head diameters, shank sizes, lengths, etc.) canbe fed through different guides.

In yet another embodiment, the tool can be configured to receivedifferent guides for fasteners of different configurations. One guidecan be for a hidden fastener, while a second guide can be for a facefastener. Each guide can include respective adjuster engagement partsadapted to engage the head size adjuster element so as to set thebackstop to accommodate either the hidden fastener or the face fastener,depending on which guide is installed in the frame.

In yet another embodiment, the tool can include a depth of driveadjuster configured to establish the depth to which a fastener is driveninto a workpiece with the tool. The depth of drive adjuster can includea top block that is movably joined with the frame. The top block can bemoved relative to the frame in the guide to set a point of engagement ofa power tool with the installation tool as the power tool rotates adriving element to advance a fastener through the guide.

In a further embodiment, a method of using the fastener installationtool is provided. The method can include pulling on a strip of collatedfasteners at a location downstream of a guide, the strip including acarrier and a plurality of fasteners, and advancing a first fastenerfrom the plurality of fasteners into a workpiece.

In still a further embodiment, the method can include attaching atension feeder to substantially only a leading end of the carrier sothat the tension feeder can pull on the carrier at substantially onlythe location downstream of the guide. Optionally, a trailing end of thecarrier remains upstream of the guide during the pulling step.

In yet a further embodiment, the method can include placing no tensionduring the pulling step and/or during the advancing step on a portion ofthe carrier between the trailing end and the guide.

In still a further embodiment, the method can include aligning the firstfastener with the bore of the guide by engaging a head of the fasteneragainst a backstop of the guide, and pulling on a shank of the firstfastener with the carrier so that a tip and/or shank of the firstfastener swings into alignment with the bore. Optionally, the carriercreates a moment about a point of contact between the head of thefastener and the backstop, thereby rotating the fastener and shankwithin a plane within which a longitudinal axis of the fastener isdisposed.

In another embodiment, the method can include attaching a leading end ofthe carrier at a location downstream of the guide to an elongatedmember; and retracting and/or rolling the elongated member onto itselfto the form of a roll. Optionally, the elongated member is joined with atensioner spring. The tensioner spring retracts the elongated membertoward the tensioner spring, thereby pulling along with the elongatedmember anything attached to it, for example. the carrier of the strip ofcollated fasteners.

In still another embodiment, the method can include securing a tensionfeeder pin to the carrier at a leading end of the strip or carrier. Thetension feeder pin is further joined with a tension feeder that performsthe pulling step. The tension feeder can be the only part of the toolthat moves the carrier past the guide and/or bore. Optionally, thetension feeder places a portion of the carrier between the leading edgeand a fastener engaging a backstop under tension, while not placing aportion of the carrier between that fastener and a trailing end of thecarrier.

In even another embodiment, a strip of collated fasteners is provided.The strip can include a row of a plurality of fasteners and a carrierincluding a leading edge and a trailing edge, between which the row offasteners is disposed. The carrier can include a starter tab extendingrearward from the leading edge. The starter tab can be void of anyfastener holes defined therein, and void of any fasteners therein.

In yet another embodiment, the carrier can include a loaded portion withwhich all the fasteners in the strip are joined. The loaded portion canextend from the trailing edge to the starter tab. The loaded portion inother portions of the carrier can include optional side notches so thatthe strip of collated fasteners can be used with other tools.

In still yet another embodiment, the starter tab can define a feederelement aperture dimensioned to receive a feeder element pintherethrough. Where the feeder element pin is attached to a tensionfeeder, the feeder can move the carrier through a guide of aninstallation tool.

In a further embodiment, the feeder element aperture can be spaced froma first fastener hole a second distance. This second distance can begreater than a first distance separating each adjacent one of theplurality of fastener holes.

In yet a further embodiment, a method of using the strip of collatedfasteners is provided. The method can include extending the carrierthrough a guide along a collated fastener path so that the starter tabprojects forward of the guide and a loaded portion of the carrier, andengaging the starter tab with a feeder to sequentially advance theplurality of fasteners through the guide. All of the fasteners arejoined with the loaded portion, which projects rearward of the guide andwhich extends from the trailing edge to the starter tab, stopping shortof that starter tab.

In another embodiment, the fastener installation tool can be configuredto attach to and be driven by virtually any type of drive tools. Manydrive tools have different sized chucks or drive components. With thisembodiment, an operator of the tool can, for example, selectivelyconnect either a large conventional chuck, for example, a ⅜ inch drivechuck to the tool, or a smaller hexagonal shaped driver to the tool.

In yet another embodiment, the tool can include a driveshaft having adrive end including a main drill drive attachment body defining anexterior surface, to which a first larger drive tool chuck can beattached. The main drill drive attachment body also can define a socketthat receives and rotationally restrains a replaceable drive bit. Thebit's drive feature can be new or worn out, and can be concealed in thedriveshaft, as it is not used anyway. A second portion of the bit,however, can extend outward beyond the main drill drive attachment bodyfor attachment to a chuck or drive component of a second drive tool,that is of a different size than the first larger drive tool.

In yet another embodiment, the tool can be configured to receive one ormore replaceable guides. Such guides can be outfitted to installdifferent types of guides in different types of application. The guidesalso can be configured to work with fasteners of different head sizesand different shank sizes unique to the application.

In still another embodiment, a replaceable guide can include a guidebody defining a guide bore and including a sidewall defining a feedslot. The slot can be configured so that a shank of a fastener can enterthe bore through the feed slot. A guide head can be joined with theguide body, above the guide bore. The guide head can include a backstopconfigured to engage a head of a fastener to facilitate tilting of theshank so as to align the fastener with the guide bore. The guide candefine a carrier slot below the backstop and above the feed slot. Thecarrier slot can slidably receive a collated fastener carrier carryingthe fastener.

The current embodiments of the fastener installation tool, strip ofcollated fasteners, and methods of use provide benefits in fastenerapplications that previously have been unachievable. For example, wherethe tool includes a tension feeder to pull the strip of collatedfasteners through a guide or nose assembly, that strip is placed underrelatively constant tension, and is unlikely to sag, become tangled,misfeed and/or jam. Further, if the strip does become jammed ormisfeeds, it is easily accessed to correct the same. The pulling of thestrip of collated fasteners through the tool—in contrast to conventionalpushing of the carrier through the tool—also leads to more consistentalignment of the fastener with a guide bore. Where the tool includes abackstop to engage a portion of a fastener, that fastener can beproperly aligned with the bore. Where the tool includes a depth of driveadjuster, the drive depth of the tool can be easily set without the useof adjustment tools. Where the guide is removable and replaceablerelative to the tool, different guides for different sized fasteners canbe easily mixed and matched with the tool depending on the job. Noadditional tools are needed for this replacement. With the strip ofcollated fasteners including a starter tab, the strip can be easilyinstalled in a tool. The starter tab can provide the primary point ofcontact with a tension feeder or other feeder to move the collated stripof fasteners through the tool.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited to the details ofoperation or to the details of construction and the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The invention may be implemented in various other embodimentsand of being practiced or being carried out in alternative ways notexpressly disclosed herein. Also, it is to be understood that thephraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“including” and “comprising” and variations thereof is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items and equivalents thereof. Further, enumeration may beused in the description of various embodiments. Unless otherwiseexpressly stated, the use of enumeration should not be construed aslimiting the invention to any specific order or number of components.Nor should the use of enumeration be construed as excluding from thescope of the invention any additional steps or components that might becombined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fastener installation tool of acurrent embodiment joined with a driving tool to advance fasteners intoa workpiece;

FIG. 2 is a rear view of the tool illustrating a tension feeder of thetool;

FIG. 3 is another rear view of the tool illustrating the tension feederhaving pulled a strip of collated fasteners;

FIG. 4 is a front view of the tool illustrating a front of the guideupon feeding the strip into the guide;

FIG. 5 is a sectional side view of the tool with the tool in a neutralmode before engaging a workpiece;

FIG. 5A is a closeup of a backstop engaging and positioning a fastenerin the guide;

FIG. 6 is a sectional side view of the tool with the tool advancing thefastener from the strip of collated fasteners;

FIG. 7 is a sectional side view of the tool with the tool in a retractedmode, with the tension feeder pulling the next, successive fastener intoalignment with a guide of the tool;

FIG. 8 is a side view of a first guide adapted to guide a firstfastener;

FIG. 9 is a perspective view of the first guide;

FIG. 10 is side sectional view of the first guide being installed in theframe of the tool, showing the setting of a fastener backstop for thatfirst guide;

FIG. 11 is a side view of a second guide adapted to guide a secondfastener, different from the first fastener;

FIG. 12 is a perspective view of the second guide;

FIG. 13 is a sectional side view of the second guide being installed ina frame of the tool, showing the different setting of a fastenerbackstop for that second guide;

FIG. 14 is a perspective view of a depth of drive adjuster associatedwith the tool in a first depth mode;

FIG. 14A is a partial section view of the depth of drive adjusterassociated with the tool in the first depth mode;

FIG. 15 is a sectional side view of the depth of drive adjuster in thefirst depth mode;

FIG. 15A is a closeup of the fastener depth of drive in the first depthmode;

FIG. 16 is a perspective view of the depth of drive adjuster in a seconddepth mode;

FIG. 16A is a partial section view of the depth of drive adjusterassociated with the tool in the second depth mode;

FIG. 17 is a sectional side view of the depth of drive adjuster in thesecond depth mode;

FIG. 17A is a closeup of the depth of drive in the second depth mode;

FIG. 18 is a perspective view of a carrier for a strip of collatedfasteners;

FIG. 19 is a perspective view of the carrier loaded with a plurality offirst fasteners;

FIG. 20 is a perspective view of an alternative carrier loaded with aplurality of second fasteners;

FIG. 20A is a perspective view of another alternative carrier for astrip of collated fasteners;

FIG. 20B is a perspective view of the other alternative carrier loadedwith a plurality of first fasteners;

FIG. 20C is a side view of the other alternative carrier traversingabout a radiused element of a tool;

FIG. 20D is a close-up view of holes defined by the other alternativecarrier and optional slits adjacent the holes;

FIG. 21 is a perspective view of a fastener installation tool of a firstalternative embodiment;

FIG. 22 is a sectional view thereof illustrating a first replaceabledrive bit in an installation and a second replaceable drive bit in adrive;

FIG. 23A is a closeup view of the installation end with the firstreplaceable drive bit installed therein, taken from view 23A of FIG. 22;

FIG. 23B is a closeup view of the drive end with the second replaceabledrive bit installed therein, taken from view 23B of FIG. 22;

FIG. 24A is a closeup view of the installation end with the firstreplaceable drive bit removed therefrom, taken from view 24A modifiedfrom FIG. 22;

FIG. 24B is a closeup view of the drive end with the second replaceabledrive bit removed therefrom taken from view 24B modified from FIG. 22;

FIG. 25 is a perspective view of the second replaceable bit beingremoved from the drive end;

FIG. 26 is a perspective view of a hold button configured to maintainthe elongated tension member under tension;

FIG. 27 is a sectional side view of the hold button in operation,holding and releasing the elongated tension member;

FIG. 28 is a sectional view of a first replaceable guide being exchangedfor a second replaceable guide relative to the tool;

FIG. 29 is a front view of a third replaceable guide;

FIG. 30 is a side sectional view of the third replaceable guide; and

FIG. 31 is a perspective view of the first, second and third replaceableguides.

DESCRIPTION OF THE CURRENT EMBODIMENTS

A current embodiment of the installation tool is illustrated in FIGS.1-17 and designated 10. Generally, the installation tool 10 isconfigured to advance a strip of collated fasteners 80 toward a guide30, so that individual fasteners from the strip are sequentially guidedthrough the guide and advanced into a workpiece 100. The installationtool can utilize a method whereby it advances the strip 80 by pulling ona leading end 81 of a carrier 85, primarily at a location downstreamfrom the guide 30 or more generally the location where the fastener isseparated from the strip 80. The carrier 85 of the strip 80 includes astarter tab 84 between the leading end 81 and a loaded portion 86 withwhich all of the fasteners are joined.

As used herein, “fastener” can include screws, nails, brads, and thelike. Optionally, an exemplary fastener, shown in FIGS. 5A and 19 caninclude a shank 107, which can be threaded or unthreaded, as well as ahead 102 joined at the uppermost portion of the shank. The head can beconfigured to include a drive feature 103, such as an outer surface, ora hole or recess defined by the head or shank. Where the drive feature103 is a hole, that hole optionally can be in the shape of a six-pointedstar. The generic name of this type of drive feature is a star drive, orhexalobular internal drive feature, which is standardized by theInternational Organization for Standardization as ISO 10644. Oneoptional type of star drive feature is a TORX drive, which drive comesin a variety of sizes, generally designated by a “T” and some number,such as T-10, T-15, T-20, T-25, T-30, T-35 and the like. TORX is a tradename of Textron, Inc. of Providence, R.I. The drive feature optionallycan be configured to connect to a drive tool, such as a rotary operatedtool, for example, a drill and/or a drive element associated with thesame, that turns or rotates the head, and thus the fastener, to advancethe fastener into a workpiece as described in further detail below.

As used herein, “collated fastener path” can include the path alongwhich the strip of collated fasteners 80 is advanced. The collatedfaster path can extend in multiple directions, for example downwardtoward the guide, transverse to the guide, and upward away from theguide. As used herein, the term “upstream” and “downstream” generallycan refer to locations relative to the guide 30, its bore 30B, and/orgenerally the location of a fastener being advanced by the tool.Upstream can refer to a location along the collated faster path that issituated before the guide, bore and/or advanced fastener. Downstream canrefer to a location along the collated faster path that is situatedafter or beyond the guide, bore and/or the advanced fastener. Upstream Uand downstream D are generally illustrated in FIG. 5; however, theirprecise locations are not limited to only those configurations andslight modifications are contemplated.

Turning now to the tool 10 illustrated in FIGS. 1-6, its components andstructure will now be described in further detail. The tool 10 caninclude a frame 20, to which the guide 30 is joined. The frame 20 canhouse a rotating drive element 25, which is rotationally constrainedand/or guided within the frame during a fastener advancing operation.The drive element 25 and the frame 20 in general are configured to beselectively and removably joined with a drive tool 109. The drive toolcan be an electric or cordless drill having a chuck adapted to join withthe drive element so that the drive tool can rotate the same. The driveelement 25 can rotate about a longitudinal axis LA. The drive element 25can include a drive end that engages a drive feature of a fastener torotate the same. The drive element also can include a chuck end that isconfigured to engage a drive tool to enable the drive tool to rotate thedrive element 25. Optionally, the drive element can be a replaceabledrive bit including a first and a second end. The drive feature,optionally in the form of the TORX drive mentioned above, can be at thefirst end. The second end can be in the form of a particular shape, forexample a hexagonal shape, square shape, elliptical shape, irregularshape, etc., configured to interface with a lower portion of thedriveshaft as described further below.

As shown in FIGS. 1-4, the frame 20 includes a first or installation orlower end 21, to which the guide 30 is joined, and a second or upper end22 to which the drive tool 109 can be joined. The frame can generally bean elongated tubular structure configured to house various components,such as the drive element 25, the guide 30 and the tension feeder 40.The frame can be of a length sufficient to enable an operator to use thetool in a standing upright configuration, while applying fasteners to adistal workpiece that optionally can be at floor level, or above or infront of the operator.

The frame 20 can include a front or upper side 20F and a rear side 20R.The front side can face away from a user operating the tool, while therear side can face toward a user operating the tool. The front side 20Fcan include a strip guide channel 20C. The strip guide channel 20C canbe U-shaped or C-shaped, and generally configured to capture the carrier85 of the strip 80 and passively guide it from the front side of theframe through the guide 30. The strip guide channel 20C can be of alength sufficient to accommodate a full length strip of collatedfasteners. When the carrier is disposed in the guide channel, it canfreely slide within the guide channel, thereby allowing the strip offasteners to move along the collated fastener path CFP. The guidechannel 20C can be located upstream U of the guide. A strip 80 disposedin the guide channel 20C can extend from that component all the way tothe guide 30 and beyond, optionally attached at its opposing end to thetension feeder 40. In most cases, before the strip of collated fastenersis emptied of its fasteners, a trailing end 82 of the carrier 85 and thestrip is disposed and slides within the guide channel 20C.

As shown in FIG. 5, the frame 20 optionally can include one or morestrip rollers 25R and 26R. These rollers are disposed at the lower end21 of the frame and are configured to provide guide surfaces to thestrip and in particular the carrier and its left 85L and right 85R sideedges. The rollers can be rotatably mounted to the frame so they rotateas the strip is pulled through the tool under tension provided via thetension feeder 40. The lowermost portions of the rollers can be alignedwith the collated fastener path CFP. The rollers can position the strip80 so that the heads of the respective fasteners 102 are aligned withthe backstop 48 so that the backstop can arrest and/or engage fastenersto properly align them with the bore and/or guide. Optionally, therollers 25R and 26R can be disposed on opposite sides of thelongitudinal axis LA of the tool 10, which longitudinal axis cancorrespond with a centerline of the drive element 25. Furtheroptionally, one of the rollers can be upstream of the drive element,while the other can be downstream of the drive element. Furtheroptionally, the rollers can be absent from the frame, or replaced withnon-rotating guide elements, such as a low friction bumper to assist inguiding the strip through the tool.

The frame 20 is joined with the tension feeder 40 as shown in FIGS. 2, 5and 15. The tension feeder can generally be adjacent the rear 20R sideof the frame, with many of its components housed substantially insidethe frame to prevent dust and debris engaging the same, potentiallydamaging its components. The tension feeder 40 can include an elongatedmember 42 that extends down the rear 20R side of the frame, optionallyfrom the upper end 22 to the lower end 21. The elongated member can be acontinuous sheet or strip of material, constructed from metal, plastic,composites and/or combinations thereof. Optionally, the elongated membercan be flexible so that it can be rolled over and over upon itself in acylindrical roll. In other cases, the elongated member can be configuredso that it does not roll upon itself and instead extends from the lowerend to the upper end of the frame and then back toward the lower end orinstallation end.

The tension feeder 40 can include a biasing member 43 joined with theelongated member 42. The biasing member 43 can be a coil spring, apowered spool, a windup mechanism, or some other mechanism configured toforcibly pull on and/or apply tension to the elongated member 42. Thebiasing member 43, sometimes referred to as a tension spring, shown inFIGS. 2 and 5, can be rotatably joined with a portion of frame 20,optionally at the upper end 22. The biasing member can be attached at apin 43P to the frame, where the pin extends from a left side to a rightside of the frame.

When in the form of a coil spring, the biasing member or tension springcan be urged to effectively furl or roll upon itself in a clockwise orcounterclockwise motion. Accordingly, because the biasing member isjoined with the elongated member 42, the biasing member exerts a tensionor pulling force on the elongated member. Further, the biasing member 43can retract the elongated member into a roll as well. In this case, theelongated member can furl or roll upon itself over and over.

Optionally, the biasing member when in the form of a coil spring canapply a constant pulling force at its distal end 43E. In other cases,the pulling force or tension exerted by the biasing member via theelongated member can decrease from a higher tension or force, to a lowertension or force as the elongated member is rolled into a roll.Generally, the tension feeder, in particular the biasing member, can beconfigured so that the tension feeder can apply a pulling force ofoptionally at least 5 pounds, further optionally at least 10 pounds,even further optionally at least 20 pounds, yet further optionally atleast 30 pounds on the collated strip of fasteners when attachedthereto. In some cases, the biasing member, when in the form of atensioner spring, can be a constant force spring that is configured tohave a relatively constant, unchanging pull on the elongated member andthus the strip from start to finish. This constant spring force canexert a pull force to whatever it is attached of optionally 1 pound to10 pounds, further optionally 2 pounds to 8 pounds, and even furtheroptionally 2 pounds to 5 pounds.

The tension feeder can be attached to the strip of collated fasteners80, as shown in FIGS. 2 and 5, with an attachment element 45. Theattachment element 45 can be joined with the end 43 of the elongatedmember 42. The attachment element can include a grasping portion 46which can enable a user to pull the elongated member in particular itsend 43E away from the roll, generally to a position as shown in FIG. 2.Where the grasping portion 46 is joined with the end 43E via a pin 46P,the frame can define a slot 20S, optionally in the rear 20R of theframe. This can enable the pin to move within and be guided by the slot.The grasping portion 43 can move on the exterior of the frame, generallyadjacent the rear surface 20R of the frame, while the elongated memberis disposed in and moves, optionally unrolling, on an interior of theframe. The grasping portion can enable a user to pull the elongatedmember to a location near the guide, the location being sufficient topass a starter tab through the guide to attach to the elongated member.The grasping portion can include a gripping surface such as a knurledsurface. In other constructions, it can include a handle or cord toassist in pulling it.

The attachment element 45, and the tension feeder 40, is configured toattach to a leading end 81 of the carrier 85. In one construction, theattachment element 45 can include a feeder element pin 47 sized anddimensioned to extend through a feeder element aperture 47 defined inthe starter tab 84 of the carrier 85 of the strip 80. The feeder elementpin 47 can be of a cylindrical construction. Optionally, the feederelement pin 47 can be bent or angled upward in a direction away from theguide to ensure that the carrier does not slip off of the element. Insome cases, the feeder element pin 47 can be angled optionally 45°,further optionally 60° and even further optionally 80° relative to thelongitudinal axis LA. Although not shown, the feeder element pin caninclude a closure to secure the leading end of the carrier to theattachment element.

The tool 10, as noted above, can include a depth of drive adjuster 50,which also can be joined with the frame as shown in FIGS. 14-17. Thedepth of drive adjuster 50 can be connected to the upper end 22 of theframe 20. The adjuster 50 can be arranged to contact a portion of thedrive tool 109 and stop its advancement toward the guide. In turn, thisstops advancement of the drive element 25 through the guide 30 and theassociated advancement of the fastener 102 into a workpiece 100. Inturn, this effectively sets the depth of drive of the fastener 102 intoworkpiece 110 as shown in FIGS. 15B and 17A. There, the respectivefasteners 102 are driven to different depths D2 and D3 into theworkpiece. For example, D2 is a lesser depth than D3. These differentdepths can be achieved by adjusting the depth of drive with the depth ofdrive adjuster 50. In fact, the depth of drive adjuster can shorten orlengthen the working length of the drive element 25 to selectively setthe depth of drive a fastener is being advanced by that drive element25.

The depth of drive adjuster 50, shown in FIGS. 14 and 15, can beassociated with a handle 50H. The handle 50H can assist a user in movingthe frame to different locations and generally operating the tool. Thehandle 50H can be rotatably mounted to the frame 20. In operation,rotation of the handle 50H can be used to adjust and set the depth ofdrive adjuster 50 to a desired drive depth for fastener. The depth ofdrive adjuster 50 can further include a stop block 54. The stop block 54can include an upper surface 59 that is configured to engage the drivetool 109, effectively stopping the drive tool from moving closer to theguide 30 of the tool 10.

The handle 50H can be mounted on a pivot axle 53 that is fixedly joinedwith the frame 20. The pivot axle 53 can be mounted in a generallyvertical slot 55 defined by the stop block 54. The stop block also candefine an adjuster slot 56 within which an adjuster pin 57 moves. Thisadjuster pin 57 can also be attached to the handle, a set distance fromthe pivot axle 53. Rotation of the handle 50H can be translated torelative movement of the adjuster pin 57 within the adjuster slot 56.This movement translates the stop block up or down within the frame,generally away from or toward the guide at the opposing end. With thehandle 50H adapted to adjust the depth of drive, no additional handtools are needed to set the depth of drive of the tool 10. Although thesystem of pins and slots in the stop block work well, other assembliesare contemplated for selectively adjusting and setting the depth ofdrive of the tool 10.

FIGS. 14-17 illustrate adjustment of the depth of drive of the tool. Inparticular, FIGS. 14 and 15 illustrate a depth of drive D2 set by thedepth of drive adjuster 50. In this first depth of drive mode, the depthof drive D2 is a relatively shallow depth. This mode is set by placingthe upper surface 59 of the stop block 54 at a high location relative tothe upper end 22 of the frame 20. Generally, the upper surface 59 inthis mode can be flush with the top edge 22E of the frame. In turn, thisarrests movement of the drive tool 109 so that the connector element 25extends only a distance H2 from one end to the other, at which itengages the fastener 102. This distance H2 enables the tool to set thedepth of drive at D2 into the workpiece 100.

In a second depth of drive mode, the depth of drive D3 is of arelatively deeper depth than D2. This mode is set by placing the uppersurface 59 of the stop block 54 at a lower location relative to theupper edge 22E of the frame 20. The upper surface 59 can be recessed adistance L2 relative to the edge 22E. In turn, this arrests movement ofthe drive tool 109 so that the connector element 25 extends a greaterdistance H3 from one end to the other, which engages the fastener 102.This distance H3 enables the tool to set the depth of drive at D3 intothe workpiece 100.

Optionally, a user can use the depth of drive adjuster 50 to set thedepth of drive of the tool and accommodate a variety of different sizedscrews as well as workpiece applications. Although shown in first andsecond depth modes, the depth drive adjuster can adjust the depth ofdrive of the tool to an infinite number of drive depths in other depthmodes. To set the depth of drive adjuster 50, a user rotates the handle50H. This can be illustrated by contrasting FIGS. 14A and 16A. Byrotating the handle 50H in direction R shown in FIG. 14A, the handlerotates about the axle 53. The pin 57 thereby engages the slot 56 whichin turn pushes the block 50 for the distance L2 downward from the edge22E. The pin 53 riding in the other slot 55 guides this movement in alinear manner.

As discussed above, the installation tool 10 includes a guide 30 that isjoined with the lower end 21 of the frame. The guide can be constructedfrom metal, plastic and/or composites and can be configured to constraina fastener as the fastener is driven, advanced and/or rotated. The guidecan be attached to the frame via bolts, pins or other fasteners.

As shown in FIGS. 5 and 10, the guide 30 can define a bore 32. The borecan be a cylindrical bore and sized so that a fastener can rotate in it,or otherwise move or advance through it. The bore can further be sizedso that its diameter is slightly larger than the diameter's widestdimension of a fastener so that the fastener can easily move through it.The bore can be sized so that it can receive only a single fastener at atime if desired. Optionally, the bore can circumferentiate a rotatingfastener 100%, at least at the very tip 30T of the guide 30.

The guide 30 also can include a guide wall 34. This guide wall 34 can bethe wall or portion of the guide against which each fastener is engagedor otherwise placed. This guide wall can be aligned with and/or form aportion of the bore 32. Generally the guide wall can be of a roundedand/or partially cylindrical contour. In other cases, the guide wall canbe flat and/or planar, depending on the application. The guide wall canbe the part of guide that the fastener initially engages. The guide wallcan engage the fastener, optionally above the bore. If desired, theguide wall can be part of the bore, an extension of the bore, and/orparallel to one or more surfaces of the bore.

The guide 30 can define a feed slot 36 which is sized to enablefasteners to be fed one by one sequentially against the sidewall and/orinto the bore. The feed slot 36 can be sized so that multiple fastenerscan be disposed in it and generally in the guide. In some cases, thefeed slot 32 can be sized so that only one succeeding fastener, after afirst or driven fastener, fits within that slot 32. The remainingsucceeding fasteners can be disposed outside the slot 36.

The feed slot 36 can lead directly to the guide wall 34. The feed slotalso can be sized so as to only allow the shank of the fasteners to passthrough that slot. For example, as shown in FIGS. 5A and 9, the slotwidth SW can be such so that only the shank 107 of the fasteners 102 and104 enter the slot 36 and thus the guide 30 as they are advanced alongthe collated fastener path. The head of the fastener, however, does notenter the slot 36 and remains generally above the bore 32 and guide wall34 until the fastener is advanced into and/or through the bore. Asfasteners are advanced into and/or through the bore, they are alignedwith that bore so that it enters the bore cleanly and consistently. Thisalignment can be facilitated via the guide wall and a backstop asdescribed in further detail below.

As shown in FIGS. 5, 5A-7 and 10, the tool 10 can include a backstop 48.The backstop can be joined with the frame 20 via one or more pins 29P.These pins 29P can be disposed in a slot 29S defined by the backstop 48.Other devices can be used to attach the backstop to the frame, dependingon the application and adjustability of the backstop. Optionally, thebackstop is structurally independent from the guide 30 and disposedgenerally above the guide 30. In this location, the backstop 48 isconfigured to engage each respective fastener of the strip of collatedfasteners as it travels along the collated fastener path CFP.

As illustrated in FIG. 5A, the backstop 48 interrupts and arrestsmovement of individual fasteners, for example the leading fastener onthe strip, as they move through the guide and tool in general. Thebackstop 48 includes engagement face 48E that is positioned andconfigured to engage each individual fastener before the fasteners areadvanced through the guide. The engagement face 48E as shown in FIG. 10can be disposed a preselected distance D5 from the longitudinal axis LA.This distance can be selected so that when the drive element 25 advancestoward the bore 32, the drive element is substantially centered on acenter of a drive feature or hole 103 of the respective fastener beingadvanced. This enables the drive element 25 to consistently engage andadvance the fasteners. The engagement face as illustrated can besubstantially planar. Optionally, the engagement face 48E can be roundedand/or angled depending on the application.

As illustrated in FIG. 5A, the engagement face 48E is disposed above thecarrier 85 of the strip 80. In this configuration, it can engage onlythe heads of the fasteners loaded on the strip. Of course, the backstopand respective engagement face can be disposed to engage other portionsof the respective fasteners on the strip, depending on the application.During operation of the tool, as mentioned above, the tension feeder 40pulls the strip 80, and in particular, the carrier 85, along thecollated fastener path so that individual fasteners enter the guide 30.As the strip is pulled, the carrier is placed under tension T, at leastbetween the attachment element and the first fastener, particularly whenthe head of a fastener, before being advanced by the tool, comes intocontact with the engagement surface 48E. Usually, while the head engagesthe backstop, the carrier remains under tension T between the associatedfastener and the point of attachment of the attachment element 45 to thecarrier.

As shown in FIG. 5A, the backstop 48, and in particular, the engagementface 48E, engages a head of a first fastener 102. This engagement canoccur at a point or surface of contact 48P. This point of contact 48P islocated above the carrier 85 which is under tension T. The tensionexerted by the carrier on the fastener below the head generates a momentM about the point of contact 48P. This moment M rotates, tips and/ortilts the shank 107 from an orientation shown in broken lines in FIG. 5Ato the orientation shown in solid lines in FIG. 5A. In so doing, thefastener rotates or moves in a plane within which the longitudinal axisLA extends. Due to the moment generated by the tension in the carrier,the shank 107 rotates or moves toward the guide wall 34 until the shankor portions thereof engage that guide wall. During this movement, thetip 105 of the fastener also can tilt, move and/or rotate toward theguide wall, all while the head of the fastener remains in a generallyconstant position, aligned with the drive element 25. With the shankand/or portions thereof engaging the guide wall and/or portions of thebore, the fastener is reasonably aligned with the bore 32 so that whenthe drive element 25 begins to advance the fastener, it will cleanly andconsistently enter that bore and be advanced through it.

Optionally, the guide can be configured to advance a variety ofdifferent types of fasteners. For example, the guide can be configuredto enable the tool to advance hidden fasteners such as those describedin U.S. Pat. No. 9,120,214 to Vandenberg, which is hereby incorporatedby reference in its entirety. This type of first guide is shown in FIGS.8-10. Alternatively, the guide can be configured to enable the tool toadvance face fasteners, which can be in the form of common deckingscrews. This type of second guide is shown in FIGS. 11-13. Optionally,different types of guides, such as the first guide and the second guidecan be removed and replaced relative to the tool to provide a broadvariety of fastener installation options via the tool on the job.

When replacing a first guide with a second guide, particularly where theguides are configured to advance fasteners having different sized heads,such as a first head diameter and a second head diameter larger than thefirst, it is helpful to ensure that the drive element 25 is consistentlycentered on or aligned with the drive feature of each fastener to beadvanced. In some cases, if the drive feature is not properly centeredon the drive feature, the drive element can misalign with the fastenersin the strip, which can lead to insufficient engagement of the driveelement with the fastener, which can lead to jamming and/or misfeedingof the fasteners. To address this, guides used with the installationtool can optionally include a head size adjuster element that indexesthe backstop to a proper location to accommodate specific fastener headsizes. A first guide 30, compatible with a screw having a first headsize, is shown in FIGS. 8-10, and a second guide 30′, compatible withanother screw having a second, larger head size, is shown in FIGS.11-13. Each of these first and second guides can include a dedicatedhead size adjuster element 38 and 38′, respectively, which eachselectively engage the backstop and move the backstop when therespective guide is installed in the tool 10.

As shown in FIG. 8, the head size adjuster element 38 is spaced adistance D7 from the rear wall 30R of the first guide 30. This head sizeadjuster element 38 can be in the form of a projection with a roundedand/or chamfered ramp 39 that assists in guiding the adjuster element 38into a corresponding hole or recess 49 in the backstop 48.

As shown in FIG. 10, when this first guide 30 is installed in the tool10, the adjuster element 38 enters the hole 49 of the backstop 48. Thebackstop 48 can be movably and/or slidably joined with the frame 20 viapins 29P. For example, the backstop can optionally move laterallyrelative to front and rear of the frame, or toward and/or away from anaxis of the bore 32, depending on location of the head and size.Accordingly, with a movable backstop, when the adjuster element 38enters the hole 49, the backstop moves or slides to align the adjusterelement and the hole. This in turn moves the engagement surface 48E aspecific distance D5 from the longitudinal axis LA. The specificdistance D5 corresponds to the head of fasteners to be used with theguide, so that when those fasteners engage the engagement surface 48E,the drive element 25 is generally centered on the respective drivefeatures of those fasteners. This in turn, ensures proper and sufficientengagement of the drive element with the drive feature for consistentadvancement of the fastener with the drive element. In some cases, wherethe backstop is not indexed relative to the longitudinal axis LA toaccommodate a specific head size and location of a drive feature, it ispossible that the drive element might not enter or engage the drivefeature sufficiently. In this off-centered condition, the drive elementmay be incapable of consistently advancing fasteners through the guide.

As shown in FIG. 11, the head size adjuster element 38′ is spaced adistance D7 from the rear wall 30R′ of the second guide 30′. This headsize adjuster element 38′ can be in the form of a projection with arounded and/or chamfered ramp 39′ that assists in guiding the adjusterelement 38′ into a corresponding hole or recess 49 in the backstop 48.

As shown in FIG. 13, when the second guide 30 is installed in the tool10, the adjuster element 38′ enters the hole 49 of the movable backstop48. Accordingly, the backstop moves or slides to align the adjusterelement and the hole. This in turn moves the engagement surface 48E aspecific distance D6 from the longitudinal axis LA. The specificdistance D6 corresponds to the head of fasteners to be used with theguide, so that when those fasteners engage the engagement surface 48E,the drive element 25 is generally centered on the respective drivefeatures of those fasteners. This in turn, ensures proper and sufficientengagement of the drive element with the drive feature for consistentadvancement of the fastener with the drive element.

As explained above, the tool 10 is designed to pull a strip 80 ofcollated fasteners through a guide so that the drive element can drivefasteners sequentially from the strip. With reference to FIGS. 1, 3 and18-19, the strip of collated fasteners for use with the tool will now bedescribed. Generally the strip 80 includes a carrier 85 in which a rowof a multiple fasteners 102 are disposed. The fasteners can be of any ofthe types described herein. For example, each of the fasteners includesa shank 107S and a head 107H. The shank can be threaded or unthreaded.The head can be the same dimension or a different dimension from theshank. As illustrated however, the head is a larger diameter than theshank diameter. The shanks of each consecutive fastener are spaced apartfrom one another so that the head of one fastener does not contact theshank of an adjacent fastener. Each of the fasteners can include an axisand a given length, depending on the application.

The carrier 85 as illustrated can be constructed from a polymericmaterial, such as polypropylene, high density polyethylene, composites,and/or frangible metals in some applications. The carrier 85 can includea leading end 81, which can terminate at a leading edge 81 E, and atrailing end 82 which can terminate at a trailing edge 82E. The leadingend and trailing end can be distal from one another, separated by lengthof the carrier 85. Optionally, the length of the carrier 85 can be suchthat the large number of fasteners, for example, optionally 50, 75, 100or more, can be associated with the carrier and held by the strip 80.

The carrier can include opposing left 85L and right 85R sides thatextend from the leading end to the trailing end. The carrier also caninclude an upper surface 85U and a lower surface 85D. Generally, whenfasteners are loaded on the carrier, the heads 107H are disposed abovethe upper surface 85U, and the shanks 107S are disposed below the lowersurface 85D. In some cases, the heads 107H can rest directly on orengage the upper surface. The upper surface can be separated from thelower surface by thickness T. This thickness optionally can be 0.001inches to 0.1 inches, further optionally 0.01 inches to 0.1 inches, orother thicknesses depending on the material from which the carrier ismade, the application tool, and the fasteners.

As shown in FIGS. 18 and 19, the strip 80 and carrier 85 can include astarter tab 84. The starter tab 84 can extend rearward from the leadingedge 81 E to a starter tab end 84E. The starter tab end 84E can befarther from the leading edge than it is from a first fastener hole FFHfor a first fastener 102A of the multiple fasteners loaded on thecarrier. The starter tab 84 can be void of any fastener holes definedtherein. Further, the starter tab can be void of and not include anyfasteners disposed within the starter tab, from the leading edge 81 E tothe starter tab end 84E. Optionally there may be zero or no fastenerholes or fasteners disposed in or otherwise associated with the startertab. Further optionally, the starter tab can be fastener hole free andfastener free in the finished state of the strip 80. In some caseshowever, there may be optional fastener holes in the starter tab,however these fastener holes are empty, that is they include zero or nofasteners located therein. In this construction, there still remainszero or no fasteners in the starter tab 84. Optionally, the starter tabcan be incapable of supporting any of the fasteners associated with thestrip therein.

The starter tab 84 can be of a length SL that is sufficient to engagethe starter tab with a feeder element and move, for example, pull aremaining portion of the carrier, for example, the loaded portion 86 ofthe strip 80. This length SL can extend from the leading edge 81 E tothe starter tab end 84E, or generally short of the first fastener holeFFH. The length SL can be optionally at least ¼ inch, further optionallyat least ½ inch, even further optionally at least ¾ inch, yet furtheroptionally at least 1 inch, even further optionally 1½ inches, stillfurther optionally 2 inches, even further optionally 3 inches or moredepending on the application and the configuration of the tool withwhich the strip is used. Further optionally, the length SL of thestarter tab 84 can be greater than any gap G that is between immediatelyadjacent fastener holes 102H defined in the loaded portion 86 of thestrip.

The starter tab 84 can include a feeder element attachment, which asshown is in the form of a feeder element aperture 87. In otherconstructions, the feeder element attachment can be in the form of aprojection, such as a hook. The feeder element attachment can be adaptedto join with a feeder of a tool to move the strip 80 through the tool,and in particular, through a guide of the tool. The feeder elementaperture 87 can extend from the lower surface 85D to the upper surface85U, completely through the carrier. The feeder element aperture can bedefined rearward from the leading edge 81 E. It also can be disposedinward from the left and right sides 85L and 85R. In this manner thefeeder element aperture can be bounded on all sides by the carrier andcompletely circumferentiated or surrounded by the carrier.

Optionally, the feeder element aperture 87 can be closer to the leadingedge 81 E than a first or lead fastener 102A and/or a first fastenerhole FFH is to the leading edge 81E. Further optionally, the feederelement aperture 87 can be sized and dimensioned to receive a feederelement pin therethrough so that a feeder element can move the carrierthrough a guide of an installation tool.

The starter tab 84 can be of sufficient tear strength to withstandengagement, such as pulling or other movement, of the carrier by aninstallation tool to sequentially advance the fastener through a guideof the installation tool. For example the starter tab can withstandoptionally at least 5 pounds of pulling force, further optionally atleast 10 pounds of pulling force, even further optionally at least 15pounds of pulling force, yet further optionally at least 20 pounds ofpulling force, even further optionally at least 25 pounds of pullingforce to pull the carrier through the installation tool.

The carrier 85 as mentioned above can include a remaining portion 86,which also can be referred to as a loaded portion of the carrier and/orstrip. This remaining portion or loaded portion is where all thefasteners 102 of the strip can be disposed. Optionally, all of thefasteners are disposed only in the remaining portion or loaded portion,generally between the starter tab 84 and trailing edge 82E. Furtheroptionally, all fasteners can be disposed only between the starter tabend 84E and the trailing edge 82E.

This remaining portion or loaded portion defines the multiple fastenerholes 102H. The first of these fastener holes 102H is a first fastenerhole FFH that is configured to receive a first or lead fastener 102A.The next hole is a second fastener hole SFH that is configured toreceive a second fastener 102B, and so on. The first fastener hole andlead fastener are the closest of the holes and fasteners to the leadingedge 81 E and/or the leading end 81. Generally however, the feederelement aperture 87 or attachment element is closer to the leading edgethan the lead fastener and the first fastener hole.

Fastener holes 102H are all also spaced from one another by a gap G.This gap G can be less than the diameter D9 of each of the respectiveheads of the fasteners. Optionally, the gap G can be small enough sothat each head of each fastener touches an adjacent head of an adjacentfastener when carried on the strip 80. In other cases, the heads ofrespective adjacent fasteners can be distanced from one another. The gapG can correspond to a first distance of separation between adjacentfastener holes. This can be contrasted with a second distance thatseparates a first fastener hole FFH from the feeder element aperture 87.In some cases, the second distance can be optionally at least greaterthan 100% of the first distance, further optionally at least 150% of thefirst distance, even further optionally at least 200% of the firstdistance, yet further optionally at least 250% of the first distance,still further optionally at least 300% of the first distance. Furtheroptionally, the first distance can be less than or equal to thediameters of individual heads of the fasteners on the strip, while thesecond distance can be greater than those diameters. Even furtheroptionally, the first distance, that is the gap G, can be of a dimensionthat is less than a head diameter D9 of individual fasteners on thestrip.

As shown in FIGS. 18 and 19, the strip and in particular, the carrier,defines no notches, recesses or cutouts in the respective left and rightsides 85L and 85R. When the strip 80 is attached to the installationtool 10 described above, such notches are irrelevant, as they do notassist in movement of the carrier through the tool. Of course, the strip80 can be used in other types of installation tools. These otherinstallation tools can utilize a pusher feeder. In this case, the pusherfeeder can include teeth that engage notches. Accordingly, the strip 80optionally can be outfitted with a plurality of notches, recesses and/orcutouts or apertures adjacent the sides of the carrier 85 to facilitateuse with these types of tools.

An alternative embodiment of the strip is shown in FIG. 20 and generallydesignated 180. This embodiment is similar to the strip embodiment abovein structure, function and operation with several exceptions. Forexample, this strip 180 includes a carrier 185 that defines a pluralityof notches in the respective sides 185R and 185L of the carrier 185.These notches can be used in conjunction with a tool having a pusherfeeder or other guide system that utilizes the notches. The strip 180also can include a starter tab 184 which is of a much shorter lengththan the starter tab noted above. The starter tab can define more thanone feeder element aperture 187A, 187B to join with an attachmentelement of a feeder system. These feeder apertures can be polygonal orsquare, rather than cylindrical or round, as with the embodiment above.

Yet another alternative embodiment of the strip is shown in FIGS. 20A,20B and 20C, and generally designated 280. This embodiment is similar tothe strip embodiments above in structure, function and operation withseveral exceptions. For example, this strip 280 includes a carrier 285in which a row of a multiple fasteners 102 are disposed. The fastenerscan be of any of the types described herein, or optionally of the typedescribed in U.S. Pat. No. 8,382,414 to Vandenberg, which isincorporated by reference in its entirety. For example, each of thefasteners includes a shank 107S and a head 107H. The shank can bethreaded or unthreaded or both. In regions where unthreaded, the shankcan have a diameter of optionally 0.100 inches to 0.175 inches, furtheroptionally 0.110 inches to 0.150 inches, even further optionally 0.115inches to 0.130 inches, and yet further optionally about 0.120 inches.The head can be the same dimension or a different dimension from theshank. As illustrated however, the head is a larger diameter than theshank diameter. For example, the head can have a diameter of optionally0.175 inches to 0.300 inches, further optionally 0.180 inches to 0.250inches, even further optionally 0.195 inches to 0.210 inches, furtheroptionally 0.120 inches to 0.200 inches, yet further optionally about0.200 inches.

The shanks of each consecutive fastener can be spaced apart from oneanother along the carrier 285 so that the head of one fastener does notcontact the head or shank of an adjacent fastener, even when traversinga radiused element. For example, as shown in FIG. 20C, the individualfasteners 102 are spaced a distance from one another so that, whentraversing a radiused element, such as a roller 26R having a roundedouter surface as shown, the adjacent fastener heads 107H optionallycontact the outer surface 26RS of the roller, but the adjacent headsoptionally do not contact one another when the carrier is bent aroundthat radiused element. That radiused element can have a radius R1 ofoptionally 1 inch to 2.5 inches, further optionally 1 inch to 2 inches,even further optionally 1.5 inches to 1.75 inches. Optionally, thecarrier can space the heads 107H so that adjacent heads on the carrier,when traversing the radiused element about an angle N of 45° to 90°,have a gap G5 between one another. This angle N can be optionally 30° to120°, further optionally 45° to 90°. This gap G5 can optionally be 0.001inches to 0.200 inches, further optionally 0.100 inches to 0.175 inches,and even further optionally about 0.110 inches to 0.160 inches. This gapG5 can be less than a gap G6 between adjacent fastener heads when thecarrier is in a flat or generally planar configuration as shown in FIGS.20A and 20B, described further below.

Further optionally, the carrier can be configured so as to space thefasteners with the adjacent heads barely contacting one another, but notenough to exert forces against one another to cause the respectiveshanks 107S to cant off at angles M or O (measured into and out from theplane of the paper of FIG. 20C) that are optionally greater than 10°,and further optionally greater than 25°, so that the shanks andfasteners will not enter the feed slot of a guide described herein.

The carrier 285 as illustrated can be constructed from a polymericmaterial, such as polypropylene, high density polyethylene, composites,and/or flexible metals in some applications. The carrier can be a singlelayer of material having a single, continuous thickness throughout,optional even adjacent the holes 202H that receive the fasteners. Forexample, the area of the carrier adjacent the holes might not includeany cups, flanges, material or extra layers that extend down from agenerally planar lower surface 285D, for example adjacent the holes202H. This optionally can be different from conventional collatedfastener strips which have such cups and flanges around the holes tostabilize and direct the screws of those strips because the tool usedwith those screws does not have the centering capability of the presenttools described herein. Thus, there, extra structure is used with thoseconventional collated strips for a purpose that is optionally irrelevantin the embodiments described herein.

The carrier can be of a variety of lengths. For example, the carrier canbe optionally about 12 inches to 36 inches, further optionally about 18inches to 24 inches, and even further optionally about 22 inches inlength from end to end or leading edge to trailing edge. The carrier canalso include a width extending from the right side 285R to the left side285L that can be optionally 0.250 inches to 1.000 inches, furtheroptionally 0.400 inches to 0.800 inches, even further optionally 0.600inches to 0.750 inches, and even further optionally 0.625 inches.

More particularly, the carrier 285 can include a leading end 281, whichcan terminate at a leading edge 281 E, and a trailing end 282 which canterminate at a trailing edge 282E. The leading end and trailing end canbe distal from one another, separated by length of the carrier 285, asdescribed above. Optionally, the length of the carrier 285 can be suchthat the large number of fasteners, for example, optionally at least 40,at least 50, at least 60, at least 75, at least 80, at least 100 ormore, can be associated with the carrier and held by the strip 280. Insome cases, the screws can be placed at specific intervals along thecarrier so that the screws have a specific frequency along the length ofthe carrier. Optionally, with the screws described herein, the carriercan include screws at an average frequency of optionally at least 2screws per inch, further optionally at least 2.5 screws per inch, evenfurther optionally at least 3 screws per inch, yet further optionally atleast 3.5 screws per inch, and yet further optionally at least 4 screwsper inch. Where the length of the carrier is 22 inches, the screws canpopulate the carrier with optionally at least 40 screws in that length,further optionally at least 45 screws in that length, even furtheroptionally at least 50 screws in that length, yet further optionally atleast 55 screws in that length, even further optionally at least 60screws in that length, and yet further optionally 80 screws in thatlength.

The carrier can include opposing left 285L and right 285R sides thatextend from the leading end to the trailing end. The carrier also caninclude an upper surface 285U and a lower surface 285D. These upper andlower surfaces optionally can be substantially flat or planar (when thecarrier is laid flat) with no projections, screw cups of othercomponents, except for the fasteners extending away from or out from theupper or lower surfaces. Generally, when fasteners are loaded on thecarrier, the heads 107H are disposed entirely above the upper surface285U, and the shanks 107S are disposed in the holes and below the lowersurface 285D. In some cases, the heads 107H can rest directly on orengage against the upper surface, but optionally the heads do not extendinto the holes until the fasteners are driven by the tool. The uppersurface can be separated from the lower surface by thickness T4. Thisthickness optionally can be 0.001 inches to 0.100 inches, furtheroptionally 0.010 inches to 0.100 inches, yet further optionally 0.040inches to 0.060 inches or other thicknesses depending on the materialfrom which the carrier is made, the application tool, and the fasteners.Optionally, this thickness can be consistent and uniform throughout thecarrier, from end to end and side to side, except where there is nothickness, for example, where the holes 202H are defined in the carrier.

Each of the fastener holes 202H can be spaced from one another a gap G6along the carrier 285. This gap G6 can be less than the diameter D10 ofeach of the respective heads 107H of the fasteners. Optionally, the gapG6 can be small enough so that each head of each fastener barelycontacts an adjacent head of an adjacent fastener when carried on thestrip 280. As shown in FIGS. 20A-20B, the heads of respective adjacentfasteners can be distanced from one another. The gap G6 can correspondto a first distance of separation between adjacent fastener holes. Thiscan be contrasted with a second distance that separates a first fastenerhole FFH1 from the feeder element aperture 287 disposed adjacent theleading end 281 and leading edge 281E. In some cases, the seconddistance can be optionally at least greater than 100% of the firstdistance, further optionally at least 150% of the first distance, evenfurther optionally at least 200% of the first distance, yet furtheroptionally at least 250% of the first distance, still further optionallyat least 300% of the first distance. Further optionally, the firstdistance can be less than or equal to the diameters of individual headsof the fasteners on the strip, while the second distance can be greaterthan those diameters. Even further optionally, the first distance, thatis, the gap G6, can be of a dimension that is less than a head diameterD10 of individual fasteners on the strip.

The relationship of the hole 202H spacing along the carrier 285 can bedescribed in connection with the centers of each of the holes as well.For example, as shown in FIG. 20D, adjacent holes 202H1 and 202H2, eachcan have geometric centers that are separated by a distance or gap G7.This distance G7 optionally can be greater than the diameters D10 of theheads 107H of fasteners stored on the strip 280. For example, thedistance G7 optionally can be 0.210 inches to 0.300 inches, furtheroptionally 0.220 inches to 0.275 inches, even further optionally 0.220inches to 0.260 inches, yet further optionally 0.201 inches to 0.260inches. The diameter of the heads optionally can be less than thesedistances. In some cases the heads diameters can be 0.200 inches, orother diameters described herein.

Each of the holes 202H also can have a particular diameter D7. Thisdiameter can be slightly less than the diameter of the unthreaded partof the shank 107S of the respective fasteners on the strip. For example,the diameter D7 can be optionally 0.001 inches less than the diameter ofthe shank, further optionally 0.010 inches less than the diameter of theshank, even further optionally 0.050 inches less than the diameter ofthe shank. With the diameter of the holes less than the diameter of theshank, when the shanks are inserted into the holes as shown in FIG. 20B,the carrier can exert a friction fit on the shanks to hold them securelyfixed thereto. In some cases, the holes can be slightly larger than thediameter of the shanks where an amount of slop is suitable for theapplication, or where a large driver is used for advancing the screws,in which case the driver can be easily withdrawn from the hole afteradvancing a fastener therethrough.

As shown in FIG. 20D, the strip 280 optionally can define one or moreminute slits 202SL adjacent and optionally contiguous with the holesthemselves. As shown, the slits are oriented substantiallyperpendicular, that is 85° to 95°, relative to the longitudinal axis CLAof the carrier. This angle of the slits can be such that when thecarrier is pulled along by an installation tool described herein, theforces exerted on any given fastener, when registered in the guide, donot cause that fastener to slide into the slit, partially out from therespective holes, and tear or substantially weaken the strip in thatregion. In some cases, this could be the case if the slit was more openand offset 45° from the centerline CLA.

As shown in FIGS. 20A and 20B, the carrier can be void of reliefapertures adjacent the holes. For example, the carrier can be configuredso there are no additional apertures extending through all or part ofthe thickness T4 of the carrier 285 adjacent the holes, to allow afastener head to pass through the carrier, through the hole when thefastener is advanced in a driving operation. The respective holes thatreceive the fasteners optionally can be the only holes passing throughthe carrier adjacent or around the fasteners. This can be the case withthe current embodiments where the heads of the fasteners are relativelysmall, as described herein. Accordingly, the heads easily pass throughthe carrier, from the upper surface, down through the respective hole,and beyond the lower surface during advancement of the same.

As shown in FIGS. 20A and 20B, the strip 280 and carrier 285 can includea starter tab 284. The starter tab 284 can extend rearward from theleading edge 281E to a starter tab end 284E. The starter tab end 284Ecan be closer to a first fastener hole FFH1 for a first fastener 102A,than to the leading edge 281E of the carrier. The starter tab end 284Eoptionally can be closer to the leading edge 281E than the firstfastener hole FFH1 within which a first fastener 102A is disposed. Thestarter tab 284 can define fastener holes 284H therein, however, in afinished carrier strip, ready to be installed in a tool, these holes284H are vacant, and without any fasteners disposed therein. Of course,in some cases the holes 284H can be absent from the starter tabaltogether. Optionally, there are no fasteners disposed within orincluded in the starter tab, from the leading edge 281E to the startertab end 284E. Further, the starter tab can be continuous with theremaining portion 286 so there is no visible end where these elementstransition to one another.

As mentioned above, there may be zero or no fastener holes or fastenersdisposed in or otherwise associated with the starter tab, or moregenerally, the starter tab can be fastener hole free and fastener freein the finished state of the strip 280. In some cases however, there maybe optional fastener holes in the starter tab, however these fastenerholes are empty, that is they include zero or no fasteners locatedtherein. In this construction, there still remains zero or no fastenersin the starter tab 284. Optionally, the starter tab can be incapable ofsupporting any of the fasteners associated with the strip therein.

The starter tab 284 can be of a length 2SL that is sufficient to engagethe starter tab with a feeder element and move, for example, pull aremaining portion of the carrier, for example, the loaded portion 286 ofthe strip 280. This length 2SL can extend from the leading edge 281E tothe starter tab end 284E, or generally short of the first fastener holeFFH1, or to the center of the first fastener hole FFH1. The length 2SLcan be optionally at least ¼ inch, further optionally at least ½ inch,even further optionally at least ¾ inch, yet further optionally at least1 inch, even further optionally 1½ inches, still further optionally 1¾inches to 2 inches, even further optionally 3 inches or more dependingon the application and the configuration of the tool with which thestrip is used. Further optionally, the length 2SL of the starter tab 284can be greater than any gap G6 that is between immediately adjacentfastener holes 202H defined in the loaded portion 286 of the strip.

The starter tab 284 can include a feeder element attachment, which asshown is in the form of a feeder element aperture 287, which can beidentical in size and shape to the other fastener holes defined by thecarrier 285. In other constructions, the feeder element attachment canbe in the form of a projection, such as a hook. The feeder elementattachment can be adapted to join with a feeder of a tool to move thestrip 280 through the tool, and in particular, through a guide of thetool. The feeder element aperture 287 can extend from the lower surface285D to the upper surface 285U, completely through the carrier and itsthickness. The feeder element aperture can be defined rearward from theleading edge 281 E. It also can be disposed inward from the left 285Land right 285R sides. The feeder element aperture can be separated fromthe first fastener hole FFH1, which is occupied by a first fastener102A, with 1, 2, 3, 4, 5, 6 or more empty holes between that feederelement aperture and the first fastener hole within which a fastener isdisposed. In this manner, the feeder element aperture can be bounded onall sides by the carrier and completely circumferentiated or surroundedby the carrier.

Optionally, as shown in FIGS. 20A and 20B, the feeder element aperturecan be in the form of one or more notches or recesses 287′ defined inone or more of the respective left 285L and right 285R sides of thecarrier. These notches can be rectangular as shown, or some other shape,such as polygonal, triangular, rounded, partially circular or othershapes. The notches can extend through the thickness of the carrier fromthe upper surface to the lower surface. With these notches, the otherfastener holes in the starter tab optionally can be deleted, with thefirst fastener holes FFH1 being the closest hole, other than thenotches, to the leading edge 281 E.

As shown in FIG. 20B, the feeder element aperture 287 or 287′ can becloser to the leading edge 281E than a first or lead fastener 102Aand/or a first fastener hole FFH1 is to the leading edge 281E. Furtheroptionally, the feeder element aperture 287 or 287′ can be sized anddimensioned to receive a feeder element pin or pins therethrough so thata feeder element can move the carrier through a guide of an installationtool.

The starter tab 284 can be of sufficient tear strength to withstandengagement, such as pulling or other movement, of the carrier by aninstallation tool to sequentially advance the fastener through a guideof the installation tool. For example the starter tab can withstandoptionally at least 5 pounds of pulling force, further optionally atleast 10 pounds of pulling force, even further optionally at least 15pounds of pulling force, yet further optionally at least 20 pounds ofpulling force, even further optionally at least 25 pounds of pullingforce to pull the carrier through the installation tool.

The carrier 285 as mentioned above can include a remaining portion 286,which also can be referred to as a loaded portion of the carrier and/orstrip. This remaining portion or loaded portion is where all thefasteners 102 of the strip can be disposed. Optionally, all of thefasteners associated with the carrier or strip can be disposed only inthe remaining portion or loaded portion, between the starter tab 284 andtrailing end 282. Further optionally, all fasteners can be disposed onlybetween the starter tab end 284E and the trailing edge 282E.

This remaining portion or loaded portion defines the multiple fastenerholes 202H. The first of these fastener holes 202H is a first fastenerhole FFH1 that is configured to receive a first or lead fastener 102A.The next hole is a second fastener hole SFH1 that is configured toreceive a second fastener 102B, and so on. The first fastener hole andlead fastener are the closest of the holes and fasteners to the leadingedge 281E and/or the leading end 281. Generally however, the feederelement aperture 287 and 287′ or attachment element is closer to theleading edge than the lead fastener and the first fastener hole.

As shown in FIGS. 20A-20C, the strip and in particular, the carrier,optionally defines no notches, recesses or cutouts in the respectiveleft 285L and right 285R sides, except for the optional one or morefeeder element apertures 287′ in the form of notches. Optionally, thecarrier defines no notches, recesses or cutouts in the respective left285L and right 285R sides along a majority of a length of the carrier.Further optionally, the carrier defines no notches, recesses or cutoutsin the respective left 285L and right 285R sides along the remainingportion on a majority of the remaining portion. Yet further optionally,the carrier defines no notches, recesses or cutouts in the respectiveleft 285L and right 285R sides along the strip between the starter taband the trailing edge. When the strip 280 is attached to theinstallation tool 10 described above, such additional notches beyond theoptional apertures 287′ are irrelevant, as they do not assist inmovement of the carrier through the tool. Of course, the strip 280 canbe used in other types of installation tools. These other installationtools can utilize a pusher feeder. In this case, the pusher feeder caninclude teeth that engage notches. Accordingly, the strip 80 optionallycan be outfitted with a plurality of notches, recesses and/or cutouts orapertures at predetermined intervals adjacent the sides of the carrierto facilitate use with these types of tools.

As shown in FIG. 20B, the carrier 285 can be void of notches, recessesand/or cutouts or apertures along the respective sides 285R and 285L ofthe carrier 285, which otherwise could be used in conjunction with atool having a pusher feeder or other guide system that utilizes thenotches. The carrier 285 optionally can be void of notches, recessesand/or cutouts or apertures, other than the feeder element apertures287′ in the starter tab 284. The carrier further optionally can be voidof notches, recesses and/or cutouts or apertures along the respectivesides 285R and 285L in the regions adjacent fasteners when the carrierstrip carries those fasteners. In some cases, notches, recesses and/orcutouts or apertures can be defined in the respective sides 285R and285L but merely for aesthetic or non-functional reasons. In these cases,the carrier is still considered to be void of notches, recesses and/orcutouts or apertures defined in the respective sides 285R and 285L.

A method of operating the tool and collated fastener strip will now bedescribed in connection with FIGS. 2-7. Generally, the method caninclude pulling on a strip 80 of collated fasteners at a locationdownstream D of a guide 30, the strip including a carrier 85 andmultiple fasteners, and advancing a first fastener into a workpiece 100.

The method can include attaching a drive tool 109, for example avariable speed drill, to the tool 10. Because the tool can be separatelyconstructed from the drive tool, various different power tools anddrills can be used to run the tool 10 of the current embodiment. Thisprovides enhanced flexibility and versatility. The power tool 109 can beattached to the drive element 25 of the tool 10. In this manner, therotational force generated by the power tool 109 can be translated tothe drive element 25 to rotate a fastener when disposed in the guide 30.

With the drive tool 109 is attached the tool 10, the user optionally canadjust the depth of drive to set the particular distance D2, D3 at whichthe fastener 102 is advanced into a workpiece 100 as shown in FIGS. 15Aand 17A. As mentioned above this can be accomplished by rotating thehandle 50H to set the block 54 a particular level relative to the frame20. The block 54 will stop advancement of the power tool and/or thedrive element toward the guide 30, thereby setting the fastener drivedepth. Of course, where there is no depth of drive adjuster, thisadjustment can be absent.

The strip 80 of collated fasteners can be loaded in the tool. The strip,and in particular, the carrier 85, can be installed in the guide channel20C, with the fasteners 102 projecting out therefrom. The sides 85R and85L of the carrier can be constrained and passively guided within thechannel 20C. The starter tab 84 however can extend beyond the guidechannel 20C. The starter tab 84 and the leading end 82 and edge 82E canbe pushed, pulled or otherwise moved initially beyond the guide 30and/or the drive element 25 by the user. Optionally, the starter tab canbe extended by the user past the backstop 48 and past the bore 32 of theguide. Generally however, the loaded portion 86 of the strip 80 does notextend beyond or past the backstop and/or the bore.

The user can pull on the strip 80 in the downstream D direction untilthe first fastener 102A in the loaded portion 86 enters the guide 30through the opening 36. The head of the fastener can engage theengagement surface 48E of the backstop 48. When the carrier is undertension, this can pull the shaft and the portion of the fastener underthe carrier in general against the guide wall 34.

The user can pull on the elongated member 42 to counter the force of thebiasing member 43 in the tension feeder 40. The user can do so bygrasping the attachment element 45, and in particular, the graspingportion 46, and pulling that portion away from the upper end 22 towardthe lower end 21 until the grasping portion achieves a suitableposition. For example, as shown in FIG. 2, as the elongated member ispulled, it uncoils coils from a roll. During the pulling, the elongatedmember remains under tension and is urged toward the tensioner spring 43at the upper end of the frame 20.

With the elongated member extended, the attachment element 47, forexample the pin, can be inserted through the feeder element aperture 87of the carrier 85. This in turn secures the tension feeder 40 generallyto the strip 80. The user can then release the elongated member and thestrip, at which point the tension feeder 40 immediately exerts a pullingforce on the starter tab 84 so that the carrier between the leading edgeand the first fastener is placed under a tension by the tension feeder.

As discussed above, the tension on the strip, in particular the startertab, pulls the head 103 of the first fastener as shown in FIG. 5 againstthe backstop 48, and in particular the engagement surface 48E. Thebackstop stops or arrests movement of the fasteners and/or the stripalong the collated fastener path so that a shank or tip of the fastenerswings into alignment with the bore. The carrier, pulling on thefastener below the head, creates a moment M, as shown in FIG. 5A. Themoment M can assist in tilting or swinging the shank 107 or otherportion of the fastener below the carrier against the guide wall 34 andgenerally into alignment with the bore 32 and its longitudinal axis.

As also discussed above, the tension exerted by the feeder element canbe exerted on the starter tab generally between the leading end 81 andthe first fastener or between the leading end 81 and any subsequentfastener after the first fastener is advanced by the tool. The tension Tmay not be exerted upstream U of the first fastener or the drive element25 in general. In this manner, the carrier 85 in the loaded portion 86might not be placed under a tension or pulling force and can bepassively held in place adjacent the tool. Further, the loaded portionor remaining portion can be passively held, and under no pushing orother force that advances the strip 80 past the drive element 25. Thiscan occur even though the starter tab remains under tension. In thiscase, a first portion of the carrier or strip is under a tension force,while a remainder or second portion upstream of the guide is not under atension force. Thus, the carrier or strip can be under differenttensions in different portions thereof, for example, a first tension ina forward portion such as the starter tab, and a second lesser tensionin a portion rearward of the starter tab, which tension might be zero.

With the head of the first fastener brought into contact with thebackstop, the drive feature 103 of the fastener is aligned with thedrive element 25. The fastener itself is also aligned with the bore 32of the guide 30. The user can begin to advance the drive element 25 toengage the fastener 102A as shown in FIG. 5. To do so, the user can movethe power tool, which is connected to the drive element, toward the noseand/or guide of the tools. The power tool 109 can be actuated to rotatethe drive element within the frame 20.

During the advancement, shown in FIG. 6, the drive element 25sufficiently engages the drive feature of the first fastener 102Afeature to rotate the fastener and push it through the fastener hole andsubsequently out of connection with the carrier 85. The drive elementextends through the fastener hole in which the first fastener 102A waspreviously disposed and continues to advance the first fastener throughthe guide 30, through the bore 32 and into a workpiece 100. The depth ofdrive of the fastener as mentioned above can be previously set by thedepth of drive adjuster 50.

After the fastener is advanced, the user retracts the drive tool 109,which in turn retracts the drive element 25 upward toward the upper endof the frame 20. Eventually, the tip of the drive element is withdrawnfrom the carrier strip and in particular the first fastener hole FFH.

Due to the tension T exerted by the tension feeder on the strip 80, asshown in FIG. 7, the tension feeder automatically pulls under tension(without further movement or action by the user) the carrier 85 andstrip 80 to move the same along the collated fastener path CFP. In sodoing, the second fastener 102B engages the backstop 48 and aligns withthe bore 32 as described above in connection with the first fastener.The advancing of the second fastener can proceed as described above inconnection with the first fastener. This procedure can be repeatedmultiple times until all of the fasteners of the strip in the loadedportion are installed or the job is complete.

The tension feeder continues to pull the strip until the last fastenersadvanced from the strip. Optionally, the tension feeder can pull thetrailing end 82 through the guide 30. The user can remove the emptycarrier at this point and install another strip of collated fasteners.If the user desires to install a different type of fastener, the usercan swap out the guide 30 for another guide, such as the guide 31 toinstall face screws into a workpiece. Of course, with the embodimentsdescribed above, when the other guide is installed, and associated headsize adjuster element can move the backstop accordingly and promoteconsistent and appropriate alignment of the drive element 21 with adrive feature of the different screw.

A first alternative embodiment of the tool is shown in FIGS. 21-31 andgenerally designated 110. This embodiment of the tool is similar and/oridentical to the current embodiments described above in structure,function and operation, with several exceptions. For example, the tool110 includes a first end, also referred to as a lower end and/or aninstallation end 121 that is distal from the second end, also referredto as an upper end or drive end 122. The installation end, like theembodiments above is where the guide 130 is located, and where fastenersare installed by the tool into a workpiece. The guide can be similar tothe guide of the above embodiment in most regards except as describedbelow. The drive end, like the embodiment above, is where the tool 110interfaces with a drive tool 107 at the drive tool's chuck 109 or drivecomponent as described below. As illustrated, the drive end 122 alsoincludes a handle 150H, which can be joined directly to the frame 120 ofthe tool 110.

As shown in FIGS. 21 and 26-27, the tool 110 can include a tensionfeeder 140 having a structure, function and operation that is similar tothe tension feeder of the embodiment above. In some cases, however, thetension feeder 140 at the attachment element 145 can be modified so asto enable an operator to reload a collated strip of fasteners using bothhands. In particular, the feeder 140 can be attached to the strip ofcollated fasteners 185, as shown in FIG. 26, with an attachment element145. This strip of collated fasteners can include multiple fastenersjoined thereto, similar to the constructions of the strips describedabove. The strip here, however, can include opposing edges or sides 187and 188. These edges can respectively define recesses 181R and 182Ralong the length of the strip or elongated carrier 185. The recessesalong the edges can be separated by tabs 181T and 182T. These tabs canbe engaged directly by the attachment element 145.

The attachment element 145 can be joined with the end 143 of theelongated member 142. The attachment element can include one or morehooks 145H1 and 145H2. The hooks can be curved like a hook as shown, oralternatively can be angled and/or perpendicular to the plate 145C (morelike a pin) of the attachment element 145. The hooks can be spaced adistance from one another so that a portion of the elongated carrierfits therebetween. The hooks can be selectively disposed in the recesses181 R and 182R on opposite sides or edges of the elongated carrier 180.The hooks can directly engage the respective tabs 181T, 182T adjacentthe recesses. When the tension feeder pulls on the attachment element145 and the respective hooks 145H1 and 145H2, those hooks engage thetabs and exert tension on the elongated carrier 180, thereby feeding itthrough the tool 110 as described in the embodiment above.

The attachment element 145 can include a grasping portion 146 which canenable a user to pull the elongated member 142, in particular its end143E, away from a roll, like that in the embodiment above, to a positionas shown in FIG. 26. The grasping portion 146 can optionally be in around, doughnut shaped form. The grasping portion 146 can be furtherjoined with a guide element 146G. This guide element 146G can beslidably registered within a slot 120S defined by the frame 120, similarto the construction of the embodiment above. The guide element and thegrasping portion 146 can be further attached to plate 145P.

The grasping portion 143 can move on the exterior of the frame adjacentthe rear surface 120R of the frame, while the elongated member isdisposed in and moves on an interior of the slot 120S. The graspingportion can enable a user to pull the elongated member to a locationnear the guide, the location being sufficient to join the hooks with theelongated carrier. The grasping portion can include a gripping surfacesuch as a knurled surface if desired.

The attachment element 145 can be pulled to the configuration shown inFIG. 26 via a user manually engaging the grasping portion 146 and movingit toward the guide 130. After the user moves the attachment element 145to the position shown there, the hooks adjacent the installation end 121are readied to attach to the carrier strip 185. Optionally, the user canengage a hold element 147 which is associated with the tension feeder,and in particular, the attachment element. This hold element can beconfigured to retain the elongated member 142 of the tension feeder 140under tension but temporarily in a fixed, extended position so that theelongated carrier 185 can be joined with the hooks of the attachmentelement. With this hold element 147 maintaining the attachment elementand elongated member in the fixed extended position mechanically, theuser can be free to use both hands to attach the carrier strip 185 tothe hooks.

As shown in FIGS. 26 and 27, the hold element 147 can include a button147B that is manually engageable by a finger F of a user. The user canpush the button 147B with a force P sufficient to move the button,compress an associated spring 147S, and thereby move an associatedextension or nut 147N. Upon this movement of the extension 147 downward,as illustrated in broken lines in FIGS. 26 and 27, the extension 147N isin a position to engage a tension stop 148, which is illustrated in theform of a fastener. The extension 147N engages the tension stop 148 at apoint of contact 147C. When the user releases the button 1478, and theextension 147N is in contact with the tension stop 148, the tension T inthe elongated member 142 is translated to the attachment element 145 andsubsequently the extension 147. This causes the extension 147N to lockagainst the tension stop 148 thereby preventing the elongated memberfrom pulling or moving substantially the attachment element out from theposition shown in FIG. 26.

Accordingly, with the tension feeder so locked, a user can use bothhands without having to continue to hold the grasping portion 146 andattach the carrier strip 185. After the carrier strip is installed, theuser can pull the grasping portion 146 slightly in direction Y. Due tothe spring 147S, the hold element 147 returns to its initial or “up”position so that the extension 147N is no longer aligned with and/orcontacting or engaging the tension stop 148. In this manner, themovement of the hold element and thus the attachment element is nolonger restricted, so the tension feeder can begin to pull the newlyloaded carrier strip 185 under tension T, and the user can operate thetool to install fasteners from the collated carrier 180.

The tool can include a driveshaft that makes the tool suitable formultiple types of drive tools. For example, the drive end of the shaft,that is, the part that is engaged by the drive tool, and in particular achuck of a tool, such as a drill, can be compatible with multiple typesand sizes of drives. Accordingly, regardless of the type of drive toolthat the user possesses, that drive tool can be easily joined with thefastener installation tool and put to use.

As shown in FIGS. 21-23, the tool 110 includes a driveshaft 160 that isrotationally mounted within the frame 120 of the tool 110. Thedriveshaft can include multiple components that are joined with oneanother as described in further detail below. Generally the driveshaft60 can extend through the frame 120 from an installation end 161 to adrive end 162. Optionally the installation end 161 and the centralportion 161C of the driveshaft 160 are concealed substantially withinthe frame 120. In some cases, however holes or apertures can be formedin the frame so that a user can see the driveshaft within it. This,however, might not be suitable for instances where the driveshaftrotates at significant speeds so as to present a safety issue.

As shown in FIGS. 22-23B, the driveshaft 60 can optionally berotationally constrained in a bushing 160B, that is, fit into the end ofthe frame 120. This bushing 160P can include bearings 160BR that engagean outer surface of the driveshaft 160. The bushing 160B also optionallycan be outfitted so that the handle 150H is attached directly to itrather than the frame 120. Of course, this can be changed with a handle150H connected directly to the frame 120 instead of the bushing 160B.

The drive end 162 can include a main drill drive attachment body 163,also referred to as a drive attachment body herein. It is at or nearthis drive attachment body that drive tools of various configurationsand sizes can be attached to the driveshaft to impart rotational forceson the driveshaft, thereby rotating the driveshaft and a drive element,for example a first replaceable drive bit 171, which engages a fastener102 to advance the fastener into the workpiece 100. The drive attachmentbody 163, as shown in FIG. 23B, extends beyond the upper end 122 of theframe and tool. Optionally, the drive attachment body 163 extends aboveand beyond the handle 150H. Drive attachment body 163 can extend beyondthe handle, the frame and the bushing to an extent sufficient to enableeither a chuck 108 of a first drive tool to be joined with the mainattachment body 163 directly (FIG. 24B), or a chuck 109 of a seconddrive tool to be joined with a second replaceable drive bit 172 (FIG.23B) in the main attachment body 163. Optionally, the chuck 108 of thefirst drive tool can be a chuck capable of interfacing with andretaining bits of up to ½ inch in diameter or more. Such chucks 108 canbe configured to clamp down on the exterior surfaces of drill bits. Manypowerful professional grade power drills are configured with such alarger chuck size. Further optionally, the chuck 109 of the second drivetool can be a chuck capable of interfacing with and retaining hexagonalshaped, standardized bits. Accordingly, the chuck 109 can be a simplehexagonal shaped socket that fits over the exposed end of thereplaceable drive bit 172. Many lower-power, homeowner grade electricdrills and electric screwdrivers can be configured with this smallerchuck size. Again, with the versatility of the tool 110, virtually anychuck size of virtually any rotating drive tool can be utilized with thetool 110.

The main attachment body 163 can include an exterior surface 163E. It isthis exterior surface 163E that can be engaged directly by a chuck 108of the first drive tool. This outer or exterior surface 163E can becylindrical or hexagonal shaped as shown in FIG. 25. This exteriorsurface 163 can include multiple angled facets and/or current facetsconfigured to interface with the corresponding services of the chuck 108of the first drive tool. Of course other shapes can be selecteddepending on the particular application and the type of chuck to beused.

The main attachment body 163 optionally can include a first dimension160D1 measured perpendicular to the longitudinal axis of the driveshaftDLA. The first dimension can be measured diametrically across a width ofthe main attachment body 163, from a first portion 160P1 of the exteriorsurface to a second portion of the exterior surface 160P2 that liesdirectly across the longitudinal axis of the driveshaft DLA. This firstdimension 160D1 can be the largest exterior surface of the mainattachment body 163 and can be sized to accommodate the chuck 108 oflarger drive tools as discussed above.

The main attachment body 163, as shown in FIGS. 23B, 24B and 25 candefine a socket 165. The socket can be structured to receive androtationally restrain replaceable drive bit, for example the secondreplaceable drive bit 172 shown in FIGS. 23B and 25. Optionally, thesocket can be of a hexagonal shape as shown in FIG. 25 so as tocorrespond to and prevent rotation of a replaceable drive bit 172 havinga similarly shaped, hexagonal configuration. The socket 165 can bedefined inward from the exterior surface 163E. Optionally, the socket165 includes a second dimension 165D2 that is taken perpendicular to thelongitudinal axis of the driveshaft DLA. The second dimension 165D2 isless than the first dimension 160D1. Likewise a corresponding dimension172D3 (FIG. 25) of the second replaceable bit 172 is less than thisdimension 165D2 of the socket so that the second replaceable bit 172 canfit within the socket 165.

Optionally, the socket 165 can include a projection or a shoulder 165F.This projection or shoulder 165S can be configured to engage anotherprojection or shoulder 172S1 of the second replaceable drive bit 172.When these shoulders engage one another as shown in FIG. 23B, thereplaceable bit 172 can no longer be pushed farther into the interior1601 of the driveshaft 160. The socket as illustrated also can beconstructed so that it completely extends through the main attachmentbody 163. In this manner, the replaceable bit 172 can be inserted intothe socket, but it bottoms out against the shoulder 165S of the socket.The shank 172S extends beyond the main attachment body and into theinterior 1601 of the driveshaft 160. Indeed, it can extend so far intothe driveshaft that the drive feature 172DF of the replaceable bit 172is located within the interior 1601 of the driveshaft 160. In thismanner, the drive feature 172DF and shank 172S of the replaceable drivebit 172 optionally can be concealed within the driveshaft 160 and/or aportion of the main attachment body 163. This is suitable because thedrive feature 172S is not utilized for driving any fasteners wheninstalled in this location of the tool. Instead, it can operate merelyas an attachment element to enable a chuck 109 to be secured to thedriveshaft 160.

With this type of construction, even in cases where the replaceabledrive bit 172 has a worn out drive feature 172DF, that drive bit canstill operate and/or function as an attachment element to facilitateattachment of the chuck 109 to the driveshaft. Optionally, it iscontemplated that either new replaceable drive bits with usable drivefeatures 172DF, that is drive features that are still able to be used toadvance fasteners 102, or used replaceable drive bits with worn outdrive features 172DF, that is drive features that are unable to besatisfactorily used to advance fasteners 102, can be used as attachmentelements. Accordingly, this provides a second use to worn-outreplaceable drive bits so they can be further used rather than simplydiscarded.

Optionally, when the replaceable drive bit 172 is installed in the mainattachment body 163, a first portion 172P1 extends into the driveshaft.Again this portion can include the shank 172S and/or the drive feature172DF. A second portion 172P2 of the replaceable drive bit 172 extendsoutward, beyond the main drill drive attachment body 163 so that it canbe satisfactorily attached to a chuck 109 of a second drive tool. Withthis configuration, an operator of the fastener installation tool canselectively connect either the chuck 108 of the first drive tool to theexterior surface of the main drill drive attachment body (withcorresponding removal of the replaceable drive bit from the mainattachment body) or the operator can attach a chuck 109 of a seconddrive tool to the second portion of the replaceable drive bit 172 thatextends outward beyond the main drill drive attachment body (when thereplaceable drive bit is installed in the main attachment body),depending on which drive tool is available to the operator.

As shown in FIGS. 23B, 24B and 25, the driveshaft and/or main attachmentbody can include a locking element 160L. This locking element can be inthe form of a locking ring that is slidable along the longitudinal axisDLA to engage and disengage bearings 160BB within an annular recess 172Aof the replaceable drive bit 172. The locking element can include aspring 160C, optionally in the form of a coil spring, that is configuredto engage the locking ring to a locked mode, as shown in FIG. 23B, inwhich the bearings 162BB engage the annular recess 172A of thereplaceable drive bit 172. In this locked mode, the replaceable bit 172cannot be easily removed from the socket 165. To remove the replaceabledrive bit 172, the locking ring 160R can be moved in direction L, thespring compresses, and the bearings disengage the annular recess 172A,thereby allowing a user to remove the replaceable drive bit 172 from thedriveshaft 160. Optionally, other configurations for retaining thereplaceable drive bit 172, the main attachment body and driveshaft canbe utilized.

As mentioned above, the second replaceable drive bit 172 can beconfigured to interface particularly with the driveshaft 160. As shownin FIG. 25, the replaceable drive bit 172 can include a shank 172S. Theshank extends from a shoulder 17251 to a drive feature 172DF. The drivefeature 172DF can be any of the types of drive features describedherein, such as a hexalobular drive feature or other screw drivefeatures. Optionally, the drive feature 172DF can include a dimension172D1 that is less than the dimension 172D2 of the bit at the opposingend 172E. The bit also can include a partially cylindrical portion 172Cthat is disposed above the shoulder 172S1. This partially cylindricalportion can define the annular recess 172A, or any type of recess,depending on the application.

Above the cylindrical portion, the second portion 170P2 can include ahexagonal shaped exterior 172H that extends to the end 172E of the bit172. In this exterior 172H, a second recess, such as a second annularrecess 172A2 can be defined. The second annular recess 172A2 is distalfrom the first annular recess 172A, and closer to the end 172E than therecess 172A. Generally, the first recess 172A can be defined in aportion of the replaceable drive bit 172 that includes a first exteriorshape, for example, a cylindrical exterior shape 172C. The secondannular recess 172A2 can be defined in a portion of the replaceabledrive bit 172 that includes a second exterior shape, for example, anangular or hexagonal exterior shape. Of course, in some applications,the first and second annular recesses can be defined in similarly shapedportions of the replaceable drive bit 172.

As shown in FIGS. 22 and 23A, the driveshaft 160 can be attached to adrive element 179. This drive element 179 can include an attachmentportion 179P that fits within a second socket 166 defined by thedriveshaft 160 and the installation end 161. The second socket 166 andthe portion 179P can be of a cylindrical or multifaceted shape, forexample, a cylindrical shape or a hexagonal shape. The drive element 179can further be joined with a first replaceable drive bit 171, which isconfigured to engage and advance fasteners with its drive feature 171DF. Optionally, the drive element 179 can include the first replaceabledrive bit 171. A portion of that replaceable drive bit 171 can bedisposed within yet another socket 179S defined by the drive element179. Further optionally, in some cases the drive element can be in theform of the replaceable drive bit 171 by itself, depending on theapplication. Returning to FIG. 23A, the installation end 161 of thedriveshaft 160 can include another locking element 161L. This lockingelement can operate and can include features similar to that of thelocking element 160L at the drive end 162 of the driveshaft.

The method of using the tool 110, and in particular its driveshaft, willnow be described. Generally, fastener installation tool 110 can includea guide 130 defining a bore, optionally attached to a frame 120. Adriveshaft 160 is rotationally mounted in the frame. The driveshaft caninclude the installation end 161 and a drive end 162 distal from theinstallation end. The drive end can include the main drill driveattachment body 163 as described above.

The first replaceable bit can be installed adjacent or in theinstallation end 161 of the driveshaft 160. This can include installingthe replaceable bit directly in the installation end 161 of thedriveshaft 160. Optionally, it can include installing a separate driveelement 179 and its respective portion 179P in the installation end 161,the driveshaft 160, and additionally installing the replaceable drivebit 171 and the socket 179S or some other connection of the driveelement 179.

A user can install a chuck 108 of the first drive tool on the mainattachment body 163 and its exterior, then secure these elements to oneanother. The user can then engage the drive tool such that the chuck 108rotates under power, thereby rotating the driveshaft 160 and the firstreplaceable drive bit 171 to advance a fastener through a bore of theguide with the first replaceable bit 171. In this operation, asdescribed in the embodiment above, a strip of collated fasteners 185 oran elongated carrier can be moved along a collated fastener path CFPpast the guide with a feeder 140.

The method can include installing the second replaceable bit 172 in thesocket 165 defined by the main drill drive attachment body 163. Wheninstalled, as mentioned above, the shank shoulder 17251 of thereplaceable drive bit 172 is disposed within and optionally concealedwithin the driveshaft 160. Further optionally, the replaceable bit canbe either a usable bit or a worn-out bit. In each respective case, theusable drive feature or worn out drive feature can be disposed within atleast a portion of the driveshaft 160 and generally inaccessibletherein. The second portion 172P2 of the replaceable drive bit 172,which is still usable, can extend from the main drill drive attachmentbody and its end 163E.

In another step, a chuck 109 of a drive tool, shown in FIG. 23B, isjoined with the second portion of the replaceable bit 172. Thereplaceable bit 172 is rotated, which in turn causes the driveshaft 160to rotate, which in turn causes the first replaceable bit 171 to rotate,and advance a fastener through a bore of the guide 130 with the firstreplaceable bit, thereby installing the fastener.

If desired, worn-out bits can be recycled for alternative uses and toserve a different function with the tool. For example, after the firstreplaceable bit 171 is worn out, it can be removed from the installationend, whether this is by taking the bit out of the driveshaft or thedrive element. The installation end, with the first replaceable bitremoved from the drive element 179, is illustrated in FIG. 24A. Thesecond replaceable bit can be removed from the drive end. The secondreplaceable bit 172 being removed from the drive end 162 is illustratedin FIG. 25. The first replaceable bit then can be installed in thesocket 165 at the drive end 162. Yet a third replaceable drive bit,optionally new or generally usable, can be installed at the installationend 161, and optionally joined the drive element 179.

The method optionally can include changing one drive tool for another.For example, after advancing fasteners with the tool 110 joined with achuck 109 of the first tool, that chuck can be removed from the secondreplaceable bit 172. The second replaceable bit can be removed from thedrive end 162. A second drive tool, optionally with a larger chuck 108can be joined with the main drill attachment body 163, and in particularits exterior surface 163E, so the second drive tool can rotate thedriveshaft and conduct fastener installation operations.

The first alternative embodiment of the tool 110 also can be configuredto include and receive replaceable guides. Such guides can beconstructed to install specific types of fasteners. For example, someguides of the embodiment can be constructed to install long screws inflat-faced surfaces. Other guides can be constructed to install shortscrews in flat-faced surfaces, yet other guides can be constructed toinstall screws in tongue and groove or porch boards. Yet other guidescan be constructed to install screws at an angle through a corner orside face of a board to fasten it to an underlying surface in a hiddenmanner.

As shown in FIG. 28, a replaceable, removable guide 130 can be installedat the installation end 121 of the tool 110. This particular guide 130can be constructed to install long screws in flat-faced surfaces. Thisguide 130 can include a guide body 180 having an upper end 180U and alower end 180L. The lower end 180L can include a flat foot 180F that isconfigured to engage flat-faced surfaces. The guide body can include alongitudinal axis GLA. The guide body 180 can define a guide bore 132that is configured to guide a rotating fastener, as with the embodimentabove. The guide bore can optionally be centered on the longitudinalaxis GLA. The guide bore can be bounded on the interior by at least oneguide wall 180G that generally assists in guiding and/or engaging thefastener 102 as it is advanced and/or fed in the guide bore. The guidebore also can be bounded by a sidewall 180S of the guide body 180. Thesidewall can transition to the guide wall from the exterior to theinterior of the body 180. The sidewall can define a feed slot 180FS thatcan be configured so a shank of a fastener 102S can move toward thelongitudinal axis and/or generally enter the bore 132 through that feedslot 180FS as the fastener is advanced by a feeder of the tool 110 asdescribed above. As shown in FIG. 28, the feed slot 180FS can extendfrom generally below a carrier slot 180CS to the foot 180F. The feedslot optionally can be of the same shape and dimension (length) as thefasteners 102 to be fed into the bore to provide adequate clearance forthe same.

The replaceable guide 130 can include a guide head 182. This guide headcan be joined with a guide body 180 at the upper end 180U of the guidebody. Optionally, the guide head 182 can be integrally formed andmonolithic with the guide body 180. In this case, the guide body andguide head are integral with one another to form a single piece guideunit. As described further below, a carrier slot 180CS can be definedthrough the single piece guide unit in at least one of the guide bodyand the guide head. The guide head 182 is generally disposed above theguide bore 132, and above the guide wall and sidewall of the guide body180. Optionally, the guide body and guide head can be screwed orfastened to one another.

The guide head 182 can be constructed to accommodate fasteners ofvarying sizes to provide an adequate amount of tilt to those fastenersrelative to the guide bore and/or guide walls and install themappropriately. For example, the dimension 182D1 of the opening in thehead 182 into which the fasteners received can be sized so that it isslightly larger than a head 102H of the fastener 102 with which theguide is compatible. The size can vary depending on the size of thescrew head. For example, for small screws, the opening can be small andfor large screws the opening can be large.

The head 182 optionally can include a backstop or fastener stop 182BSattached thereto and/or integral therewith. This backstop can operatesimilar to the backstops described above with the current embodiment andtherefore will not be described again here. Suffice it to say that thebackstop is configured to engage ahead of a fastener to facilitatetilting of the shank 102S against the guide wall 180G so as to align thefastener with the guide bore satisfactorily. The backstop 180BS of thisembodiment however goes with the guide. In this manner, guides withspecific utility backstops can be installed, so that no furtheradjustment for the guide is needed.

Another feature of the replaceable guides is the carrier slot 180CS. Thecarrier slot 180CS is built into the each replaceable guide and formsthe area or region through which a carrier 185 or strip of collatedfasteners travels along the collated fastener path CFP as a feeder pullsthe strip under tension T through the guide 130. The carrier slot can bedimensioned to slidably receive the collated fastener carrier 185 ofwhatever size, thickness or width desired. The carrier slot can belocated between the head and the body of the guide. The carrier slot180CS can be transverse to the longitudinal axis GLA of the guide. Thecarrier slot 180CS also can be located generally under or adjacent thehead 182, sufficiently close to the backstop 182BS so that the head 102Hof a fastener collides with the backstop 182BS to provide a tiltingaction to the shank 102S as described above. Optionally, the carrierslot 180CS is defined below the backstop and above the feed slot of theguide.

The carrier slot 180CS can be bounded by an upper surface 180CSU and alower surface 180CSL. The lower surface 180CSL can be constructed toengage a lower surface 185L of the carrier strip 185, while the uppersurface 185CSU can be configured to engage an upper surface 185U of thecarrier strip 185. The lower surface 185CSL, however can be interruptedby a void 185V as it extends across the longitudinal axis GLA. The uppersurface 185CSU, however, can include a surface that extends completelyacross the longitudinal axis GLA from one side to the opposing side. Theupper surface of the carrier slot also can transition to the engagementsurface 182E of the backstop 182BS. The carrier slot further can includesidewalls 182S that form the sides of the carrier slot and extend fromthe upper surface to the lower surface of the carrier slot. Optionally,where the tool or guide is configured to feed a collated strip such asthe one in FIGS. 20A-20B, the void 185V can be absent from the carrierslot, so that the lower surface of the carrier slot 185CSL extendscompletely across the longitudinal axis GLA from one side to theopposing side of the slot. This is because the collated strip there isflat, and without projections or cups extending out from the bottomsurface of that strip. With the void removed, in some cases, there canbe less likelihood that a head of a fastener is pulled under tensionforce into the void, thereby causing an improper feed of the fastenerinto the bore.

In some applications, the guide 130 can include an alignment feature180F. This alignment feature can enable precise and consistentregistration of the guide with the frame 120. The alignment feature caninclude a recess 120R as defined by the frame 120. The guide 130 caninclude a setscrew 180ES. The setscrew can be located so as to registerprecisely in the recess 120R so that the guide does not rotate thereinor relative to the frame. Further optionally, the setscrew can bereplaced for some other type of alignment feature, such as a projection,depending on the application.

To join the replaceable guide 130 with the lower end 121 of the tool110, a locking member 190 can be utilized as shown in FIG. 28. Thelocking member can include a recess 190R that is defined by the guide130. The recess 190R can be defined by the guide body 180 as shown, butof course, in other cases, the recess can be formed in the guide head182, or it can overlap both. The locking member can include a fastener190F that is joined with a portion of the frame 120. The fastener 190Fcan be threaded into a plate 190P and can extend into the recess 190R.The fastener 190F can be tightened sufficiently to lockably and sturdilysecure the replaceable guide 130 to the frame 120.

With this construction, the fastener 190F can be loosened to quicklyreplace one guide for another. For example, as shown in FIG. 28, theguide 130 can be removed as shown via arrow R from the end of the tool110. In its place, another replaceable guide 230 can be installed viaarrow I in the end 121 of the tool 110. Optionally, this replaceableguide can be the same type of guide or a different type of guide when adifferent type of screw or application is in order. As a furtherexample, a user may use the guide 130 to install long screws, flat-facedinto thicker decking. At some point, the boards of the decking may bethinner. In this case, a user can remove the guide 130 in direction Rand replace it with a short screw guide 230 installed in direction I inthe tool. This short screw guide 230 can include a shorter feed slot280F to accommodate the shorter screws.

A variety of different types of replaceable guides can be used inconnection with the tool as shown in FIGS. 28-31. Another type ofreplaceable guide 330 is shown in FIGS. 29-31. This replacement guideincludes the head 382 and body 380 as described above, as well as thecarrier slot 380CS and the locking member recess 390R. The foot 380F ofthis guide however can be configured to include an alignment projection380A and a positioning plate 380P. With this construction, thereplaceable guide 330 can be used to install fasteners within a crevicebetween workpieces, such as boards where no gap is established betweenthose workpieces upon installation or thereafter. The alignmentprojection and the plate can be similar to those described in theembodiments above is desired.

Other statements that may be helpful in understanding the embodimentsherein can include the following:

S1. A method of installing a fastener in a workpiece comprising:

-   -   pulling on a strip of collated fasteners at a location        downstream of a guide defining a bore, the strip including a        carrier and a plurality of fasteners;    -   advancing a first fastener from the plurality of fasteners        through the bore and into a workpiece.

S2. The method of statement S1 wherein the guide includes a head sizeadjuster element adapted to interface with a backstop corresponding to afirst fastener head size, comprising engaging the head size adjusterelement with the backstop so that a drive element aligns with a drivefeature of the first fastener.

S3. The method of statement S2 comprising sliding the backstop away froman axis of the bore during the engaging step.

S4. The method of statement S2 comprising sliding or moving the backstopaway from an axis of the bore during the engaging step.

S5. The method of statement S1 comprising:

-   -   removing the guide from a frame, the guide being a first guide        having a first bore of a first diameter;    -   replacing a second guide in the frame in place of the first        guide, the second guide having a second bore of a second        diameter larger than the first diameter.

S6. The method of statement S1 comprising adjusting a backstopassociated with the guide so that the guide can guide a second fastenerhaving a different diameter head than a head of the first fastener.

S7. The method of statement S1 comprising passively supporting thecarrier upstream of the guide.

S8. The method of statement S7 comprising providing a channel adjacent aframe to which the guide is joined, the channel being of a width toenable the carrier to slide longitudinally through the channel duringthe pulling step.

S9. The method of statement S1 comprising adjusting a depth of drive ofthe installation tool to accommodate a plurality of fasteners having aplurality of preselected driving depths.

S10. The method of statement S1 comprising providing a frame, the framehaving a drive rod extending from adjacent the guide past a drive toolend, and adjusting in the drive tool end a tool stop to selectivelyarrest movement of the drive tool toward the guide.

S11. The method of statement S10 wherein the frame is joined with ahandle, wherein the handle is connected to the tool stop, comprisingrotating the handle to selectively move the tool stop relative to thedrive tool end so that a drive element joined with the frame onlyextends past the nose a preselected distance.

S12. The method of statement S10 comprising providing a tension feederthat includes an elongate member adapted to coil retractably into anelongate member roll, wherein the tension feeder includes a hookconfigured to attach to a leading end of the strip.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are usedto assist in describing the invention based on the orientation of theembodiments shown in the illustrations. The use of directional termsshould not be interpreted to limit the invention to any specificorientation(s).

The above description is that of current embodiments of the invention.Various alterations and changes can be made without departing from thebroader aspects of the invention as defined in the appended claims,which are to be interpreted in accordance with the principles of patentlaw including the doctrine of equivalents. This disclosure is presentedfor illustrative purposes and should not be interpreted as an exhaustivedescription of all embodiments of the invention or to limit the scope ofthe claims to the specific elements illustrated or described inconnection with these embodiments. For example, and without limitation,any individual element(s) of the described invention may be replaced byalternative elements that provide substantially similar functionality orotherwise provide adequate operation. This includes, for example,presently known alternative elements, such as those that might becurrently known to one skilled in the art, and alternative elements thatmay be developed in the future, such as those that one skilled in theart might, upon development, recognize as an alternative. Further, thedisclosed embodiments include a plurality of features that are describedin concert and that might cooperatively provide a collection ofbenefits. The present invention is not limited to only those embodimentsthat include all of these features or that provide all of the statedbenefits, except to the extent otherwise expressly set forth in theissued claims. Any reference to claim elements in the singular, forexample, using the articles “a,” “an,” “the” or “said,” is not to beconstrued as limiting the element to the singular. Any reference toclaim elements as “at least one of X, Y and Z” is meant to include anyone of X, Y or Z individually, and any combination of X, Y and Z, forexample, X, Y, Z; X, Y; X, Z; and Y, Z.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A strip of collatedfasteners for use in an associated fastener driving tool for driving afastener from the strip, in sequential order, into a workpiece, thestrip of collated fasteners comprising: a row of a plurality offasteners arranged substantially parallel to each other, each fastenerhaving a shank and a head, the head being larger in diameter than theshank, the shanks being spaced apart from each other so that the head ofa fastener does not contact the shank of an adjacent fastener, eachshank defining an axis, each fasteners having a length; a carrierincluding a leading edge and a trailing edge, and opposing left andright sides between which the row of the plurality of fasteners isdisposed, wherein the carrier includes an upper surface and a lowersurface, with the head of each fastener being entirely above the uppersurface and the shank being below the lower surface, wherein the carrierincludes a starter tab extending rearward from the leading edge to astarter tab end that is closer to the leading edge than a first fastenerof the plurality of fasteners, the starter tab being void of anyfastener therein before installation in the fastener driving tool,wherein the starter tab is of a length sufficient to engage the startertab with a feeder element and pull a remaining portion of the carrier,wherein the plurality of fasteners are disposed only in the remainingportion, between the starter tab end and the trailing edge.
 2. The stripof collated fasteners of claim 1, wherein the starter tab defines afeeder element aperture, wherein the feeder element aperture includes afirst notch on a first side of the carrier and a second notch on asecond side of the carrier, wherein the first and second sides are voidof any other notches along a majority of each of the respective firstand second sides.
 3. The strip of collated fasteners of claim 2, whereinthe remaining portion defines the plurality of fastener holes in whichthe plurality of fasteners is disposed, wherein the remaining portion isvoid of any other notches along the first and second sides.
 4. The stripof collated fasteners of claim 3, wherein each of the plurality offastener holes are separated from one another by a hole gap, wherein thehole gap is less than a head diameter of each of the plurality offasteners.
 5. The strip of collated fasteners of claim 1, whereinrespective heads of each of the plurality of fasteners contact oneanother when the plurality of fasteners are disposed in the respectiveplurality of fastener holes.
 6. The strip of collated fasteners of claim1, wherein the starter tab extends the length from the leading edge ofthe carrier to the starter tab end, wherein the length is at least ¾inch, wherein the starter tab defines a plurality of fastener holes thatare unfilled by fasteners before the carrier is installed in a tool. 7.The strip of collated fasteners of claim 1, wherein the carrier is of asingle layer of polymeric material of a uniform thickness from theleading edge to the trailing edge, wherein the lower surface issubstantially planar, with no projections other than the shanks of theplurality of fasteners extending downward from the lower surface,wherein the heads of each of the plurality of fasteners are disposedentirely above the upper surface, without projecting downward to thelower surface before the carrier is installed on the fastener drivingtool, wherein the carrier defines a plurality of fastener holes in theremaining portion so the plurality of fasteners in the remaining portionhave an average frequency of at least two screws per inch along alongitudinal axis of the carrier, wherein each of the plurality offastener holes have centers, wherein the centers of adjacent ones of theplurality of fastener holes are spaced a distance of 0.200 inches to0.260 inches from one another, wherein each fastener of the plurality offasteners includes a head that has a diameter of 0.120 inches to 0.200inches. wherein the carrier is void of any apertures extending throughthe thickness in areas adjacent the fastener holes.
 8. The strip ofcollated fasteners of claim 7, wherein the carrier defines a firstfastener hole within which the first fastener is disposed, wherein thecarrier defines a second fastener hole within which a second fastener isdisposed, wherein the first fastener hole is disposed a first distancefrom the second fastener hole, wherein the feeder element aperture isdisposed a second distance from the first fastener, wherein the seconddistance is greater than the first distance.
 9. The strip of collatedfasteners of claim 1, wherein a feeder element aperture is definedrearward from the leading edge, wherein the plurality of fasteners aredisposed through a plurality of fastener holes defined by the carrier,each of the fastener holes separated from an adjacent fastener hole by afirst distance, wherein the feeder element aperture is spaced a seconddistance from a first fastener hole within which the first fastener isdisposed, wherein the second distance is at least 150% of the firstdistance.
 10. A strip of collated fasteners for use in an associatedfastener driving tool for driving a fastener from the strip, insequential order, into a workpiece, the strip of collated fastenerscomprising: a row of a plurality of fasteners arranged substantiallyparallel to each other, each fastener having a shank and a head, thehead having a diameter that is greater than a diameter of the shank, theshanks being spaced apart from each other so that the head of a fastenerdoes not contact the shank of an adjacent fastener, each shank definingan axis, the fasteners each having a length; a carrier including aleading edge and a trailing edge, and opposing left and right sidebetween which the row of the plurality of fasteners is disposed, whereinthe carrier includes a starter tab extending rearward from the leadingedge, the starter tab being void of any fasteners therein, wherein thecarrier includes a loaded portion with which all of the plurality offasteners are joined, wherein the loaded portion extends from thetrailing edge to the starter tab.
 11. The strip of collated fasteners ofclaim 10, wherein the starter tab extends from the leading edge to theloaded portion of the carrier, wherein the starter tab is ½ inch to 1¾inches in length and configured to engage a feeder element to facilitatemovement of the loaded portion of the carrier, wherein the starter tabincludes a plurality of empty fastener holes between the leading edgeand first fastener.
 12. The strip of collated fasteners of claim 10,wherein the starter tab defines a feeder element aperture configured toengage a feeder element, whereby the feeder element can move the carrierthrough a guide of an installation tool.
 13. The strip of collatedfasteners of claim 12, wherein the feeder element aperture is spacedfrom a first hole of a plurality of fastener holes a second distance,the second distance being greater than a first distance separating eachadjacent one of the plurality of fastener holes.
 14. The strip ofcollated fasteners of claim 10, wherein the loaded portion defines afirst fastener hole separated a first distance from an adjacent secondfastener hole defined by the loaded portion, wherein the first hole isseparated from a feeder element aperture defined by the starter tab asecond distance, wherein the first distance is less than the diameter ofthe head, wherein the second distance is greater than the diameter ofthe head.
 15. The strip of collated fasteners of claim 10, wherein thestarter tab is at least 1 inch in length, wherein the plurality offasteners includes at least 50 fasteners, wherein the carrier is 18inches to 24 inches long, wherein the carrier defines a plurality offastener holes, wherein each of the plurality of fastener holes havecenters, wherein the centers of adjacent ones of the plurality offastener holes are spaced a distance of 0.201 inches to 0.260 inchesfrom one another.
 16. The strip of collated fasteners of claim 10,wherein the starter tab is of a sufficient tear strength to withstand atleast 5 pounds of pulling force to pull the carrier through a fastenerinstallation tool.
 17. The strip of collated fasteners of claim 9,wherein the plurality of fasteners includes a lead fastener that is theclosest of the plurality of fasteners to the leading edge, wherein eachof the plurality of fasteners are equidistant from one another, whereinthe starter tab defines a feeder element aperture, wherein the feederelement aperture is closer to the leading edge than the lead fastener.18. A method of using a strip of collated fasteners, the methodcomprising: providing a carrier including a leading edge and a trailingedge, the carrier joined with a plurality of fasteners, the carrierincluding a starter tab extending rearward from the leading edge, thestarter tab being void of any fasteners therein, extending the carrierthrough a guide along a collated fastener path so that the starter tabprojects forward of the guide, and a loaded portion of the carrier, withwhich all of the plurality of fasteners are joined, projects rearward ofthe guide, the loaded portion extending from the trailing edge to thestarter tab; and engaging the starter tab with a feeder to sequentiallyadvance the plurality of fasteners through the guide.
 19. The method ofclaim 18, wherein the feeder pulls on substantially only the starter tabto advance the plurality of fasteners.
 20. The method of claim 18,wherein during the engaging step, the starter tab pulls the loadedportion through the guide.